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Road King Headlight Nacelle

- JoBear

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This page shows how I installed a Harley Davidson Road King headlight nacelle on my Kawasaki Vulcan Nomad. My inspiration and guide was the Road King headlight nacelle mod previously done by Time2Ride. A link to his work is here.

Figure 1

This was my bike with the stock front-end. The Nomad front-end is 1" too wide to install the R-K headlight nacelle, so I swapped it with the front-end from a 2003 Vulcan Classic 1500. I have to especially thank Phillip Reece who swapped front-ends with me.

Figure 2

This is the bike with the front-end removed. The Nomad stearing stem is a larger diameter than that for the Vulcan Classic, so a machine shop modified both triple-trees to use the stearing stem from the other.

Figure 3

The Vulcan Classic 1500 front-end installed and test fit of the H-D headlight nacelle. I first tried the headlight nacelle over the top triple-tree clamp, but did not like the gap between the bottom of the headlight nacelle and the lower triple-tree clamp.

Figure 4

I then test fit the nacelle below the top tripletree clamp and decided that was how I will mount it

 

Figure 5

I wanted to utilize the stock Road King lightbar, spotlights, and turn signals along with the quick release windshield. To do this, I needed to make up a bracket setup to use the existing mounting holes in the headlight nacelle halves

 

Figure 6

I originally used a hole saw and drilled holes for the fork tubes to go through. This worked but I later decided to open up the entire area under the top triple-tree clamp so that each half could be mount from the side to ease in removal and installation in the future.

 

Figure 7

This is how it looked during one of the test fits. I took my time fitting the nacelle, marking the areas to cut or trim and testing fitting it again and again.

Figure 8

I later cut out most of the area under the top triple-tree clamp. This made it must easier to work with to do the job right. As you may notice, the brackets were too long so they were cut as not to hang below the nacelle.

Figure 9

You can see how the whole setup is lining up. I am pleased with the work, so far.

Figure 10

The lightbar mounts like it would on a stock Road King. I had to add washers to make up the gap on the top mounting bolts, but it turned out good.

Figure 11

The quick release windshield works perfectly with the lightbar. I used the quick release hardware which I ordered from Harley Davidson for a Road King.

Figure 12

Here you see the finished prouct. I painted the headlight nacelle black to go along with the black and grey paint theme I have planned for the bike in the near future

 

 

 


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