I have built a dual headlight setup for my 2016 Suzuki Gixxer, from scratch. While the body of the headlights are made of metal, the lenses are made of glass. Although the lenses seem to be resistant to smaller level everyday hazards, I assume that they can still get damaged if exposed to larger size hazards, such as a stone chips flying towards the headlight from the tyre of a fast-moving truck. To prevent them from getting damaged, I have recently installed a custom-made headlight guard, which again I have made using a sheet of plexiglass.
I bought a sheet of plexiglass from an online store for around INR 500. The sheet is transparent therefore, it will not obstruct the light beam, and also flexible enough to not break easily. To give it the desired shape and size I have used a small hacksaw to cut it. The process is tedious since the sheet can break if too much force is applied while cutting. Since I do not have a drill, I have used a nail, heated on fire, to make holes on the sheet. Again, to make the holes, it is necessary that the nail is hot enough so that it can penetrate the sheet without applying much force.
Last but not least, the guard has been installed using metal bolts, therefore, it is extremely important to use rubber washers between the guard and the metal surfaces to prevent it getting cracked due to excessive force or vibrations.
Since it may not be easy to understand the process by reading, do checkout the video below, regarding the same on YouTube.
