Yamaha XS650 Cafe Racer: Custom Headlight Brackets

Custom headlight brackets for the Yamaha XS 650 cafe racer...

Custom headlight brackets for the Yamaha XS 650 cafe racer…

Danny has been hard at work on the Yamaha XS650 Cafe Racer, making a bunch of custom parts to finish up the build, in style.  The latest piece to be made on the lathe and mill is the set of bespoke headlight brackets…

Not content to settle for the generic, readily available brackets that you see on many builds, Danny set about designing a simple, sturdy set, that will hold a pair of good looking ‘ears’ to mount the headlight.

Starting from a solid piece of round-stock aluminum, the challenge was to make the perfectly rounded shape to fit over the forks, but leave an ‘arm’ jutting out, where the ears will slide into and be secured with two bolts.  This requires working with round stock, but cutting a non-round shape.  Always a bit of a pain in the ass.  Patience was tested, but the results will be worth it.

In the photo above, the pieces have been turned and milled, using Prussian Blue dye to mark the lines.  After getting the shape just right, Danny then used a saw blade style attachment on the mill to shave off the excess, making the brackets exactly 1″.  Using 1″ flat stock, he will then make the ears, which will fit snug in the cut-out gaps, cut in the brackets.

These are going to be simple, but gorgeous accents to the Yamaha XS650 cafe racer build.  These hand-made parts are adding a lot to the overall look of the build, keeping it unique and subtle at the same time.

Stay tuned for the follow up, which will show the ears cut to size, and decorated with a tasty design…

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