Drilling bottom mounting holes - 1/4"

Setting up the headlight post hole. It is 1 cm from the end

Almost done

this should have been the 1st picture. The raw channel stock. 2 inches wide from Home Despot
Pick an end of the channel stock.
Measure in 1" from that end and draw a line across it.
On the bench grinder use the edge of the wheel to grind a shark fin shape into each curved up end of the U. The points of the fins should be pointing to the 1" line with the longer side of the fin toward the end of the channel and the more obtuse angle toward the rest of the channel's length.
Make sure you grind all the way down to the flat portion of the channel.

Now tighten the end of the channel in a vice so that the 1" line is just visible above the top of the vice's jaw and aligned with it. Attach a magnetic bubble level to the top of channel lengthwise. With a firm grip on the top of the channel carefully bend it down until the bubble level shows nearly perfect horizontal bubble.

With a measuring tape measure 2 5/8" from the end and around the bend and draw a line. Using a hacksaw cut off the channel at that line.

Clean up cut end with grinder.
Apply tape as seen above and layout holes as described above.
Drill, grind, sand and paint. It's Miller time!

Note: the 2 5/8" cutoff point was ideal for the headlight I'm using but depending on the height of the headlight you may want to play with this measurement for the best fit.

Happy New Years!

Mounted to triple tree

Done!

Some notes about the Highway Hawk headlight.
The wiring fits inside but it's a tight fit.
The pivots bolt is junk. the hex head strips out before its even halfway tight. Replace it with something more robust.
The little bezel screws are tiny evil little things. Not fun to chase them around when dropped.

Thanks!