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K1200RS - H7 HID Installation

Following is a description of the process/method I used to install the XenonShop Phillips H7 HID kit on my K12RS. As with all of the projects posted on this site, I make no claim as to this being the only, much less the best approach to this installation. The following is intended to be nothing more than my effort to document my project and to share it with other like minded folks who can not leave well enough alone. In other words, proceed at your own risk..........
For bodywork and headlamp removal/installation , I can do no better than to refer you to Scot Marburgers excellent instructions which can be found on his site at Gunsmoke.  

 
Note: right-click on any thumbnail for a 800x600 view 
Click to enlarge Pictured at left is the XenonShop HID kit as received. In addition to the items shown, I used the following:
  • 12v SPST automotive relay (20a contacts or better)
  • 16ga stranded wire (for power feed and ground)
  • 18ga stranded wire (for relay control)
  • In-line fuse holder w/20a fuse
  • 4 female spade terminals (connection at relay)
  • 2 male spade terminals (connections at original H7 plug)
  • 2 ring terminals (power feed and ground)
  • Epoxy (5-minute &30-minute)
  • Basswood/balsa for CFEC cover (hold on, it's ok, you'll see)
  • Misc: heat shrink tubing, tie wraps, solder, paint etc

The H7 adapter ring must be assembled to the xenon lamp base. As with a halogen bulb, take care not to touch the glass portion of the lamp. I used the cardboard tube that comes with the lamp as a holder. Make sure that the adapter ring and lamp base are both clean. I also had to deburr the hole of the ring in order for it to center up on the base. Using the 5 minute epoxy, attach the ring to the lamp base as shown, making sure that ring is centered on the lamp base and that the tab is aligned with the insulated lamp wire as shown.

Shown here is the xenon lamp installed into the headlamp. The base of the xenon lamp is larger in dia. than the H7, which requires a little adjustment to the stock bulb retainer. A standard H7 based bulb will still mount and be held securely with this re-calibrated retainer.
In order for the new connector to fit beneath the original lamp cover, it is necessary to cut a hole in the factory cover. Shown at left is a picture of a simple wooden fixture used to hold the cover for drilling. In my never ending tendency to over complicate everything, I used this fixture to hold the cover at an angle that would allow the hole saw to cut in the same axis as the centerline of the bulb/connector. Several passes were made, moving the cut toward the center of the cover each cut. Also shown is where the pilot hole was drilled into the cover at the point which aligns with the center of the lamp.
This picture shows the cover after the initial 1.5" hole has been drilled and shows the relative position of the hole to the new lamp. Subsequent holes were drilled "below" this hole (using the fixture).
The completed clearance hole after clean up is shown at left. The extra cutout at the bottom of the hole is to allow additional room for the connector cable.
These pictures  show the  cover installed over the HID connector. Although the connector almost fits behind the cover in the area directly behind the lamp, the connector is long and protrudes into the sloped area of the cover. This required removal of more material than would have been the case for a taller cylindrically shaped connector.
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