I'VE SOLVED IT!!!!
Whelp, maybe....
So the problem is that the H4 LED bulb (actually its heat sink) sticks out too far in the back. And a shorter reflector/housing could solve this.
So you know what could also potentially solve this? What if we just move the bulb forward in the same reflector housing?
Yeah, something's got to give, so get out your tin-snips or hacksaw, but this might not be as bad as you think. Of course, if I mess this up, I'm either out a $40 LED bulb, or a headlight reflector housing (which may cost from $20-100) I forget what I got mine for. Who cares, let's do it! I'll be the test pig on this one.
My fanless H4 LED from SBL has a flimsy plastic rim/plate which marries up to the headlight reflector housing. Other bulbs I have seen have this same "H4-shaped" plate, but are often aluminum.
So here's what I'm going to do.... I'll take my tin-snips and trim that plastic plate down, so it now slides right through and further into the headlight housing. At least how mine is constructed, the heat sink is wider than that H4 mounting hole, and my plan is to cram that right up against the back edge of my reflector housing. The normal H4 bulb clips won't hold it in place, so I'll add some additional wire and maybe some rubber bands if I want to be truly elegant. I am hoping that the fins on the heat sink as they are crammed against the edges of the housing will prevent my bulb from rotating while my bike shakes its way down the interstate.
On my bulb, the heat sink is about 1/2" back from the H4 plate, so I think that could potentially give me just the clearance I need to get it to fit with a normal headlight ring and the OEM speedo cable.
This will definitely change the beam pattern thrown by my reflector, but I don't care horribly much. It's probably illegal too, so take this with a grain of salt. I'm just a hobbyist brainstorming to solve a problem.
Attached is a diagram of what I'm thinking...
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RE: my auxiliary light clusters: yes, they're super cheap. I hope they work, but many people have had good luck for them. I'm not really concerned with keeping my bike period correct, and yes I will be mounting them on top of my handlebars. I actually was planning on putting one underneath the normal headlight like you (Bert) did, but I think mine might be just a little too wide for that. Haven't measured though.
I live in Baltimore, and I commute on I-95 towards DC. It's one of the most harrowing autoways in the country. Because of the population density and the traffic, nobody gets pulled over for things like non-DOT lights, etc. Also, I love living in Baltimore City because you don't get pulled over for dumb stuff by bored officers. I love this town, and needless to say, our officers are not bored.
I'm more concerned with my personal safety, and more lights means more safer. I also plan to aim the LED clusters down at the road in front of me to have more visibility... it'll help cars zooming up behind me at 85mph hopefully see me and swerve in time. That said, when I'm on a Sunday ride through the small towns and twisties, I will be sure to keep my non-DOT (somewhat blinding) aux clusters in their 'off' position.
I love the look of the amber or yellowed headlights, but since I'm planning to run these LED clusters anyway, I went with the super-white. To each his own. I realize most Enfielders love the bikes for the history, and want to preserve that about them. I may be that way in a few years, and everything I've modified on my bike, I've kept the OEM parts in a box in my basement in order to do a full restore if I feel like it someday.
For a tail light, I am using a housing from Dime City Cycles (of questionable quality), but I recently crammed this light into it:
https://www.radiantz.com/Harley-Davidson-Bullet-style-turn-signals-p/00073-hdts.htm . The LED cluster is from Radiantz and it is way brighter than a stock incandescent. I have a second LED cluster that came with it, and I plan to mount that to my bike under a fender or something. It's an 1157 dual function LED cluster, red-then-brighter-red, so I use it as a brake light.
Do you guys think my DIY trimming of the LED headlight bulb will work?
Any other crazy ideas floating around out there?
Fingers crossed!!!!
Cheers,
Chuck