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Thread: Gerbing Permanent Controller Install DIY

  1. #31
    Honey Badger Semper_Fi's Avatar
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    There is no science to the next part - to align the hole drilling for the LED, I used a straight edge and I aligned it with the + cross-hair (yellow arrow) of where to drill the shaft hole and then drew the line.

    Then I got on the bike to see if it was lined up - it wasn't - so I drew the corrected one you see below and proceeded to drill the hole.
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    Last edited by Semper_Fi; 03-13-2010 at 04:41 PM.

  2. #32
    Honey Badger Semper_Fi's Avatar
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    If you plan on mouting the controller in the same general area as i did below is shown where the mounting post for the panel is in relation to where you are drilling.

    Something to be aware of - consider it a soft caution.
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    Last edited by Semper_Fi; 03-11-2010 at 05:04 PM.

  3. #33
    Honey Badger Semper_Fi's Avatar
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    Note - the Side Panel goes for about $780.00 be sure you want to do this.

    After you start drilling there is no going back.

    Some tips for drilling:

    • the instructions call out the sizes you need (9/32" for the shaft and 7/64" for the LED) or in metric-speak 7.25mm/2.77mm respectively
    • Don't start with those - start with smaller pilot holes and work your way up.
    • Use an electric drill as you have more control on speed (at least I do on mine)
    • Drill from the finished paint side - this will leave a cleaner hole and minize paint flacking by the outer edges of the drill point
    • Slow speed, even pressure - if you have sharp bits it will go quick
    • try to have a drill size that is one level below what is stated in the instructions - you will then be able to gauge how much drill opening you have left.
    • Last but not least - go slow, evenly and take your time
    Commitment Time!!
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    Last edited by Semper_Fi; 03-13-2010 at 04:41 PM.

  4. #34
    Honey Badger Semper_Fi's Avatar
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    Installation of the shaft/PCB/LED
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  5. #35
    Honey Badger Semper_Fi's Avatar
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    This shows a ziptie that was added to the panel post support, helping to provide support for the PCB. A 3/16" hole must be drilled in the support for the ziptie. Do NOT overtighten the ziptie!
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    Last edited by Semper_Fi; 03-11-2010 at 05:05 PM.

  6. #36
    Honey Badger Semper_Fi's Avatar
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    Additional cable routing and support.

    NOTE - the cable tie down shown are available at any electrical hobby shop - Radio Shack, electical section in Lowe's or HD
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    Last edited by Semper_Fi; 03-11-2010 at 05:12 PM.

  7. #37
    Honey Badger Semper_Fi's Avatar
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    Finished product....

    Works well and it is easily viewed and accessed from the driver's position.

    The only issue with visibilty is when the sun is shining on it but you can easily provide some shade with your hand to see the flashing frequency.
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