The headlight in this beast was trashed. Some kid tipped it over and bent the heck out of the chrome. Held together with duct tape. Somewhat miraculously, I got all the goo off and was able to straighen to almost a circle.  Any good hints?  A new ring is like 180. Ouch.  Plus there is some pride in bringing things back from the brink.
the bulb? Trashed. No glass. Wiring intact. A sealed beam unit of some sort. A nos one is unobtanium.  6v.

here are some photos of last couple days progress

You are never going to get it perfectly round or blemish free, but you can take out a great deal of the mis shape by gently forming by hand and tapping with a soft mallet over an anvil horn or a smooth edged piece of scaffold tube held in a vice.

After that, take out the smaller dings by placing it on something like a barstool or a very firm cushion and very gently tap them out from the inside with a small body hammer or failing that, a 2oz ballpein hammer.  Body hammer would be best.

Getting into the folded areas will require a small dolly placed behind and gently tapping out with something able to get into the corners.

It takes time but is very rewarding when you have finished.

Great ideas. It’s already gone from a negative five to a 7.  It was trashed. The bend was crazy.  I wish I would have had a before picture.  

this headlight is a lot different than my dt3. Seems the wiring is permanent to the bulb? Bulb and glass seems like one sealed unit.  Ideas?  Anything I see aftermarket 6v does not have the proper lead. I guess I could solder. 

I tend to look at these things a little "left field", so to speak.

Check out CMSNL and Partzilla for which other models used the same headlight rim as your bike. Once you have this list, you can search for headlights for these models as well as your own GT80, both original and aftermarket. Take care if looking at an AT1/2/3 with a sealed beam, as these are 12v.

A bike that uses the same rim should also use the same beam direction paraphernalia. However, as you suggest, you might need to buy/manufacture/adapt the wiring pigtail for it.
 

The headlamp rim seems to be the same part as the AT1,2,3?

I might have a used one and a non-sealed beam headlight lens that uses a bulb holder like the early bikes and non-USA models. I don't think I have the bulb holder.

(Also, it's always a good idea to mention what you're working on... if it wasn't for the picture of the oil tank and remembering your story about your Dad and fixing up your childhood 1974 GT80 I would never have guessed.)

Okay I see plenty for older bikes, like 40 brand new nos.

the part for 74 GT80: 261-84315-61

68 as2:  183-84315-61

if my understanding is correct, this is exactly the same part color and material just a different model?

 

 

No.

Thanks!!

This is not an easy animal to find!
appears to be 5 in in diameter…