H-D XLH, FXD, FXR Conversion
Converting Top Mounted Headlight to Bottom Mounted Headlight

Drilling a hole in the lower tree of an XLH, FXD or FXR with top mounted headlights.

Step 1 - Remove The Stock Headlight
Step 2 - Mark The Center Of The Tree
Step 3 - Center Punch The Lower Tree
Step 4 - Drill A Pilot Hole Using A Center Drill
Step 5 - Drill A .375 (3/8") Screw Using A Sub Drill
Step 6 - Counter Bore for 3/8" Screw
Step 7 - Drill Out Hole To .404 Using A "Y" Stub Drill

Tool Supplier:
• McMaster Carr
  (562) 692-5911
  (Call for current prices)

Tool List:
• Center Drill: #3, 1/4" Body, 7/64 Drill Point, 82º & 90º Counter Sinks, High-Speed Steel
  Part #: 2915A147      About $9
• Drill Bit: .375 (3/8") Stub (Or Machine Screw Length) High-Speed Steel Drill
  Part #: 2896A34      About $5
• Drill Bit: Letter "Y", Stub (Or Machine Screw Length) High-Speed Steel Drill
  Part #: 2896A37      About $5
• 9/16" Counter Bore Bit With Built-In 3/8" Pilot
  Part #: 2919A18      About $30
      • For 3/8" screw
      • .562 dia. counter bore
      • .375 pilot
      • 1/2" shank - 1/2" capacity drill chuck required
      • 6-1/2" overall length, can be cut shorter to fit drill & counter bore bit between front
        tire and lower tree