We did a bit of work yesterday on fitting our custom numberplate/headlight idea.  We first needed to take some measurements, and then mark and drill the angle brackets.

Steady with the spring punch, pilot hole...

Aluminum can be tough to drill, due to its relative softness.  Push to hard with the press, and it will "bite" or wander off line.  Patience is required and the bit size needs to be stepped up slowly.

A too-small bit chuck was pressed into service by Mr. S, and when it was being tightened, it slipped...

Ooops.  Learn from your teacher, kids!

Once the first mounting holes were drilled, we refitted the brackets to the headlight ears.  We actually switched around the orientation, based on the narrowness of the forks, and the relative width of the numberplate.

With our carbon-fibre numberplate nearly ready, we wanted to make sure we didn't mess up with our measuring, and drill a hole in the wrong spot.  So the original aluminum "buck" was used as the template, with measured test holes drilled and labeled.  We now have a guide to where the mounting holes need to be drilled in the carbon piece (holes #3 on each side). And well check that for fitment,  Then we'll fit the 4 1/2" light, and then finally mount the headlight permanently.  The offset idea won't quite work as it will foul the mounting bracket.  Maybe the centre is the way to go...