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Old September 20th, 2016, 10:24 PM   #1
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Joined: Jul 2014
From: California
Posts: 884

Hyper Lights V2.0 - Complete!

The wait is finally over! (Sort of... will get to that later)

Last year, I created a custom auxiliary light kit for our bikes, nicknamed Hyper Lights V1. After many requests for more, I embarked on a journey to make more kits specifically for the Hypermotard and Hyperstrada community. It turned into quite the learning process and was delayed by multiple hurdles including crashing my motorcycle... oops. Most of the changes are behind the scenes - so you will look at the kit and ask, "He took a year to make the same damn thing?!". I thought I'd take the opportunity to explain the changes and what it took to get there.

Here are some of the main changes to the kit:
- All new circuitry for higher efficiency, brightness, and some added adjustability.
- Updated housing for styling and passive cooling.
- New electronics mounting location for ease of wire routing.
- More plug & play installation for easier bike maintenance.

The caveat? As of now I don't have any available. I have been bench-testing and bike-testing for quite a while, to ensure its reliability. So far so good! So before too long, I plan to have 10 kits available for sale - one of which will be the prototype kit at a discounted price because it might have a speck of dirt or bug guts on it. Right now I am targeting $650 plus shipping (about $15 for Domestic US 1-3 day), for the complete bolt-on kit.

Yes, there are other great options out there. Denali, Baja Designs, Clearwater, just to name a few. This is merely a hobby and passion for me, and I enjoy providing a unique option to the community.


Features:
-100% Made in USA using domestic parts whenever possible
-CNC machined 6061 aluminum housing, mounting bracket, etc.
-Heat dissipating mil-spec black coating
-Flexible polymer mounting points
-Replaceable, hard-coat shatterproof lens covers
-3-wire plug & play (with minimal modification) signal to use factory handlebar switch for Low/High operation
*I will also give the option to use your own switch. You just need a 3 position switch (off, low, high)
-All wires cut to length, no relays, soldering, crimping, or extra switches needed
-Fused power supply @ the battery
-Up/down adjustable mounting system for different bike setups (luggage, fork height, lowered version, preference, etc)
-Custom optic pattern for both tight turns and higher speeds
-Full install PDF with pictures will be included


Specifications:
-Cree XM-L2 4750K LEDs (pure white) producing ~6,500 lumens
-12V input @ 65W on High, 6W on Low


Pictures:
Here are some pictures along the way, and then the final product.

CAD of the light and mounting bracket


Some raw materials!


CAM'ing the junction box cover


Mounting bracket next to a test-fit drawing


Shiny metal objects


Machine doing machine things


Hot metal-on-metal action


One of many Digikey orders. So. Many. Plastic. Bags.


Doing some endurance testing on the bench. Trying to determine how hot it would get without any heat sinking or airflow.


Testing LEDs for 8 hours requires good cooling. Here they are in a Pyrex full of ice water on a giant heatsink.


Some on-bike testing in the garage. Dat waveform.


Onto the installed pics:

Junction box with side fairing removed


Side view


Artistic down low view


Tada!
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Old September 21st, 2016, 07:57 AM   #2
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Joined: Feb 2016
From: Nakhonpathom, Thailand
Posts: 6

I Ride: 15 Hypermotard 821 SP, 16 Multistrada 1200 Enduro
Hi Kuksul08,

I have been checking the thread since some time.
Wow, the finished product looks really awesome.
Please see PM

Hope to hear a good news from you

Cheers
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Old September 21st, 2016, 02:43 PM   #3
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I Ride: Hyperstrada, Transalp & Fireblade
Fucking amazing write up man, really appreciate you sharing that with us kuksul!
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Old September 22nd, 2016, 03:27 AM   #4
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I Ride: 2013 White Strada
Gorgeous craftsmanship. I'd quit your day job, though looks like you probably do very well with a "hobby" like that.

Hope the original "I'm in" list applies.
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Old September 22nd, 2016, 04:55 AM   #5
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Looks great. The stock headlight is beyond pathetic on these bikes.

Count me in as well.
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Old September 22nd, 2016, 08:46 AM   #6
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Quote:
Originally Posted by Jokeshopbeard View Post
Fucking amazing write up man, really appreciate you sharing that with us kuksul!
Thank you sir

Quote:
Originally Posted by gatdammit View Post
Gorgeous craftsmanship. I'd quit your day job, though looks like you probably do very well with a "hobby" like that.

Hope the original "I'm in" list applies.
My day job involves lots of sitting at a desk, so I need to get out my creative energy some way!

I will definitely go by the original list. I'm expecting a number of people to drop out since I took so long.

Quote:
Originally Posted by rss29 View Post
Looks great. The stock headlight is beyond pathetic on these bikes.

Count me in as well.
Thanks.

Funny enough my stock headlight bulb just burned out recently. I went with a Philips x-treme vision +130 or something as a replacement. It looks surprisingly good color-wise, and has a little more punch.
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Old September 24th, 2016, 06:29 AM   #7
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Beautiful job.
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Old September 24th, 2016, 12:27 PM   #8
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im in as I said in the other thread. just let me know when and how
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Old September 25th, 2016, 04:11 PM   #9
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aux lights

Please add me to the list. REALLY dig these.
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Old September 25th, 2016, 10:33 PM   #10
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I Ride: Hyperstrada 2014 MY
Looks fantastic , great job. I'm still in !
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