I was looking at my Hawthorne the other day and thought that it could use a headlight visor. I’ve seen some Delta sealed beam bike headlights with headlight visors built into the trim ring, but they are usually expensive and I don’t see them about that often. I decided I would have to make a visor. It seemed to me that the bottom edge of a chrome fender would make for a good headlight visor, and I decided to try it. The finished visor actually looks real good on the headlight, I think… This took me about 30 minutes start to finish: http://i44.tinypic.com/28vaf12.jpg (Before pic: http://i42.tinypic.com/2v7wi7s.jpg) I could have probably done it in 15 minutes, but we didn’t have power when I made the visor and I had to cut the fender with a hacksaw rather than a wheel. I used a measuring tape as a flexible straight edge, and drew a cut line with my sharpie marker. http://i40.tinypic.com/20jsqpu.jpg Being that I was using a hacksaw to cut the fender, I thought it would be best to cut the fender along the brace, using the brace edge as a natural guide/straight edge for my saw. That worked mint. The Delta sealed beam headlights have a tiny screw on top that holds the light trim ring in place- this screw has enough thread to hold a thin piece of steel like my cut fender tip without a problem. I test fitted the visor on the headlight quickly, ( http://i40.tinypic.com/otixqp.jpg) and finding it to fit OK, I found the middle of the fender tip with my tape measure. I marked the middle along the straight edge of the fender tip with a sharpie, and went to work drilling an appropriately sized hole for the brass headlight screw. It took me a little while to get the hole just right in respect to size, and I also realized that my fender straight edge wasn’t so straight. A little filing and I was done. http://i44.tinypic.com/28vaf12.jpg I thought someone might find this post to be useful.
