LED Motorcycle Headlight

Step 3 Part 1: Making the Array Plate

Part 1: Step 3
Highlight the finished sketch and then press the PrntScrn key
Past the image into any graphics program such as GIMP or Photoshop and then select only the yellow sketch lines and blue sketch nodes. Copy that part of the image and paste into a new image, then fill those colors with black.
Save that image as a .png file.

Part 1: Step 4
Place the image onto a page in Microsoft Word or Open Office. Format it's size on the page to match the size of the part in the CAD file.

Put one sheet of full sheet label paper face down into your printer and print out the page.

Use scissors to cut out the template, then apply it to the protective film/paper of the plastic sheet.

Part 1: Step 5
Drill the holes where indicated by the template, then cut the part to the shape indicated using tin snips, a band saw, or a scroll saw.

If you are making the part out of thin plastic such as 1/16th" thickness polycarbonate or ABS it will be very easy to cut with tin snips, so a power tool won't even be required. However a band saw or scroll saw will produce much cleaner edges and will allow you to cut more complex shapes.

Part 1: Step 6
Once the piece is made, test fit it in the fixture.

I wasn't complete happy with the look of the first piece I made nor did I like the lens that the fixture came with.
I ended up making a replacement out of gray PVC and the clear base disc from a CD-R spindle.