Sunday 26 April 2020

High Lights

So, with lots of spare time, a high-level brake light is a long-overdue upgrade; with Zedster being so low it has worried me that some brain-dead driver may not see my brakes.

The first problem is that all the high-level brake lights I could find are made to attach to a flat surface and I want to attach mine to my roll-bar. So, time to roll out my amazing, bracket-making skills. Two pieces cut out of ally sheet and spray-painted black:

 

These will bend round the rollbar and provide a flat surface to attach the brake light too, with a couple of tabs to fit into the feet of the light unit.

Next was the electrics - I had to get the brake signal from one of the rear brake lights. This involved taking off the rear wheel, cutting off the existing wire to the rear light and making up a new link with an extra branch (the blue section in the pic below) for the new light:


To make it neat, I really needed the wire to feed up through the rollbar, so I had to - gulp - drill holes in my so-far pristine rollbar:


One at the foot, another up where the light goes. It took me an hour to feed the wire through and then fish it out at the bottom with a butchered wire coat hanger. A hole in the boot carpet through to the inspection hole in the chassis for the top suspension bolt and I could connect the wire up to my new plug. A quick test of the brake pedal to make sure the connections all worked and the light works and then a couple of p-clips riveted into the rear panel hold the wire out of the way of the suspension.

The brackets were then bent round the rollbar (the paint split in places, so I had to re-do that at the end), the tabs bent over and trial-fitted into the feet of the light unit (difficult to explain - trust me). Firstly, I had to trim the tabs as they were too big and then the cheap light unit fell apart in my hands! Fortunately, it just clips back together - not the greatest quality. With the brackets bent into place, 4 more holes in my rollbar (in for a penny...) and 2 rivets per bracket to hold them in place.

Finally, a couple more layers of spray paint to patch up the peeled sections, a final coat of lacquer and job done:




It's not the greatest piece of work ever (not much of mine is) but it's nice and solid, neat and should do the job.