SO, my light bar was installed by the PO on top of the roof's plastic. I'm afraid if I hit a low hanging branch the light is going to break, and probably rip off the roof damaging both.

I'm thinking of where to move it, and best I can think of is just an inch or so above the crossbar above my shins. The easiest way to do this would be we to drill 2x 8mm holes straight through the frame. Otherwise I don't see anywhere really where this pilot has been drilled into much.

Would it really hurt any value? Structually I think 2x8mm holes won't change anything.

Pic

It wont hurt anything but the feelings of the pilot purists! lol!

Do you have any way to fabricate anything? Weld?

If I were doing it. Id go to McMaster carr, find a split clamp that fits the tube and mod as necessary to hold the brackets. Could be as simple as a couple drilled/taped holes in the split clamp or full on fab city.

Not sure if this is an option for you but here is how I have my light mounted on my FL350.
Light is mounted on a bar and the bar is held onto the roll hoop with cable clamps.

Edit: Option 2 is make a new roof lid out of metal.

The reason I put my light under the roof lid was because of roll overs.

I used some aluminum with 2 bends and used the bolts for the upper cage.

That's what I was going to suggest, that's why I asked his fab skills.

If you are not overly concerned with price you can look into handlebar accessory clamps.

Here is an example.

https://alexnld.com/product/32mm-1-25in ... al-silver/

If that cross bar is the same size as the 350 Ody's cross bar in the same location, you could use the mounting brackets for the FL350 headlights.

Rand

Actually, Oddy above just gave me an idea. I'll use some stainless hose clamps to clamp the light's mounting bracket to the forward cross bar. Failing that I have some more extreme options as well. Let me try this.

Seems like lots of good options provided here.
My opinion would be not to use those stainless hose clamps unless it is cushioned with something. Any hard mount may shake your expensive light to bits. Don't like that idea without rubber mount of some kind.

The cross-bar is wrapped with foam tape. Actually I've decided on using stainless u-bolts. Its ideal and would catch the mount of the light which is flat perfect.

maybe you already saw this, a couple of examples, one is mine
http://www.pilotodyssey.com/PO/viewtopic.php?f=1&t=16600