LED Headlight Cover for BMW vehicles

thingiverse

The newer motorcycles have distinct headlight housings compared to older models. Two different cover designs are available, one for each version, so it's essential to identify the correct model by inspecting the original covers. **OLDER VERSION (MODEL A)** The original cover features 4 locks on its base and a removable rubber seal. **NEWER VERSION (MODEL B)** The original cover has 3 locks on its base, with a glued-on rubber seal and a wide bar on top. I recently purchased an LED H7 lamp for my BMW F800R but encountered a problem - the heatsink on the back prevented it from fitting inside the high beam headlight housing. After searching online, I found a design that was close to what I needed but not exactly what I wanted. Inspired by this design, I created one from scratch with an elaborate profile that allowed for better grip. My F800R is a 2011 model, so I'm using the Model A covers. The low beam original cover can accommodate the LED with heatsink, but it needs to be forced in slightly and leaves no room for the fan to breathe. The high beam doesn't fit at all, so I designed custom covers for both high and low beams, leaving about 1cm of space between the fan and the back of the cover to allow proper airflow. I kept the original rubber seals, which work well with the custom covers and provide a tight seal just like the originals. For Model B, the original rubber seals are not removable, so I used a piece of foam similar to neoprene with glue on one side that can be cut to fit and works as a seal. You can use other materials, but for Model B, it needs to be elastic and the right size/thickness to create pressure and secure the cover in place; otherwise, the cover won't hold or lock properly. You might need to adjust the headlight case all the way to the front if your suspension hits the back of the cases when turning fully right or left. Both BMW F800GS and F800R models use the same headlight housing, so these covers work for both. However, F1200GS uses a different cover size from the F800 models, with both high and low beams being the same size. I 3D printed the covers using PLA and have been using them for several months without issues. These designs have at least a dozen copies already in use on various motorcycles without complaints, so they've undergone a good level of testing. It took around 9 hours to print the pair of covers with 0.2mm layer height and supports. **MATERIAL UPDATE** After about one and a half to two years of continuous use, the PLA starts to warp and loses its tight fit, causing some covers to fall off. Not surprisingly, PLA is not suitable for outdoor use. Consider using PETG for a long-term solution. The LEDs (55W each) are quite good, providing better visibility than traditional H7s and fast enough for high beam flashing. They're easy to find online for around 25€ a pair. **LED UPDATE** The price of these LEDs has dropped over time; you can now find them for less than 20€ a pair.