Low Cost LED Headlight

Modern LED lamps are now available that are able to produce light output comparable to
incandescent type bulbs with greatly reduced power consumption. Older motorcycles often have
charging systems with marginal capacity and the headlight is by far the greatest power consumer.
The use of LED bulbs in headlights offers an opportunity to significantly reduce the electrical
load on the motorcycles charging system. The potential benefits of this include longer battery
life and the ability to run additional electrical accessories. Many older British motorcycles use
the British pre-focus bulbs with the P36d type base. Suitable low cost LED bulbs with this base
do not seem to be readily available at this time so here is a way to convert the low cost units that
are available.
Suitable low cost LED bulbs from Asia can be purchased via EBay. The cost delivered is about
$20 each. Many variations are available with obscure branding and vague model numbers so
here are some things to consider when making a choice
1) Do you want high and low beam. Not all bulbs are dual power.
2) Many old British motorcycles have positive ground electrical systems. LEDs are polarity
sensitive. Choose an LED that is electrically isolated from ground if you have a positive
ground motorcycle.
3) Watch out for clearance. Most high power LEDs will have a large housing at the base.
This may include a heat sink, fan and the driver electronics that may foul items in side
your headlight housing.

Some bulbs have the driver electronics in a small external housing. This may help reduce the size
of the bulb at the base. Most importantly, having the electronics separate reduces the possibility
that the lamp frame will be a ground/power connection causing polarity problems in a positive
ground system. The bulbs often include multiple socket adapter rings and a spring.
The bulb illustrated had a high/low power rating of 18/12 watts with a corresponding light output
rating of 2000/1350 lumens. (1620/1080) For comparison typical incandescent bulbs are rated at
50/40 watts and would produce 875/700 lumens.

The least expensive way to mount the bulb is to modify one of the included adaper rings so that
it has three tabs to match the slots on the back of the Lucas reflector. This can be done by hand
with a grinder. The modified adapter ring is fitted to the bulb, followed by the included spring
and a large washer. The washer fits into the rear of the reflector in place of the original bulb
collar allowing the modified asapter ring to lock into the slots in the reflector and held in place
by the tension of the spring.

Another option is to make your own adapter ring to fit the rear of the reflector as shown. This is
a neater solution but making the adapter ring shown requires access to a lathe.

If you have a standard 7 unit, the complete headlight assembly (lens/reflector) can be replaced
by one that accepts one of the standard adapters supplied with the lamp. These are sold for
converting older automotive sealed beam headlights to accept halogen bulbs with a H4 base.
They start at about $30 but do not have provision for the pilot lamp at that price.

For a negative ground motorcycles the connections are a simple matter of following the
instructions included with the lamp. For positive ground first be sure that the lamp has no
electrical connection to its frame/housing because that will cause a short to the motorcycle
frame. The body of the lamp must be insulated from the motorcycle frame in a positive ground
system. If no high/low beam function is required simply connect the lamp positive to frame and
lamp negative to wire that supplied the prior lamp. The simplest way to achieve a high/low beam
function is using a relay to switch the power. Choose a relay with double pole double throw
(DPDT) contacts rated for at least two amps with a coil voltage rating to match the motorcycle
voltage. (6 volt or 12 volt) The example is an NTE brand relay model R14-11D10-12. It has
DPDT contacts rated at 10 amps and a 12 volt coil. The connections to this relay can be by
Faston type connectors, plug in base or soldered. In the example the connections are soldered.

Actual measured current draw for the LED was 1 amp on low and 1.5 amps on high. The
incandescent bulb drew 3 amps on low and 4 amps on high.
The LED lamp emitted a very bright white light.
Focus was not ideal. This may not bother you if you do not ride at night and your goal is day
time safety with reduced drain. For night use it would be prudent to pay attention to positioning
the lamp for good focus for better visibility and to avoid blinding other drivers.