Nate asked how it looks mounted. i have to confess I cheated. i have another bike devoid of plastic. I fitted my light to this other bike and away i went. Measuring every thing up the lens I made would not stick out past the fairing.
With the concrete plug the full size of the lens and placed on a piece of 9mm ply the same shape as the bottom of the plug. The acrylic will bend to form a radius at the bottom as it is pressed over the concrete. When i cut the lens off just above this bend It worked out to be the right size for my projectors. If one is using the H1 projectors you would have to measure everything first.
Now to $’s
35w hid fast start ballast $100.60
http://www.ebay.com.au/itm/151188200056?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1439.l26492.5” HID projectors $100 pr
http://www.aliexpress.com/item/FX-R-HID-PROJECTOR-LENS-BI-XENON/505448791.htmlbulbs Phillips D2S model # 85122
from The retrofit source $95 pr There are cheaper ones but from looking at forums they are not as good. These have 2yr warranty.
http://www.theretrofitsource.com/components/bulbs/d2s-philips-85135.html#.VBqOSksWdz8plugs for bulbs/HID $15 pr about same on ebay.
http://www.theretrofitsource.com/accessories/amp-d2s-ballast-adapter-90-degree.html#.VBqRGEsWdz8acrylic industrial grade uv proofed 450 by 350mm $10 local mob
9mm ply and some 45 by 19 pine $25 from bunnings
Total $360.68.
stuff I already had
2mm aluminium for base
bunch drills, hole saw, drill press, files etc
kitchen oven, lots of time for first attempt.
would be easier now with experimenting done.
Please note I have used the D2S units which are not plug and play, need new base, plate.
The H1 units just screw in. I have enjoyed the challenge of the D2S.
and well pleased with result and value for $