My modded bike light! (v.grab a beer, lots o'pics!)

[Arkayne]

My girlfriend's PlanetBike Dual-Spot bike light bulb blew last month (sorry dear, the HID is for ME ME ME). It featured a mini halogen bulb and a single 5mm white led powered by 2 AA's. Sooooooo, since the incan was burned and the cheapy led was practically useless, I decided to yank out the innards and see what I could do with a Lux III setup.

I set the following criteria for this, my 2nd major mod attempt ever, bike light project:

1) It had to have self contained rechargeable batteries w/socket to connect the charger
2) It had to last for at least 20 mins
3) It had to have a decent heatsink since the case is plastic
4) It had to output more light than the stock incan/led setup
5) It had to look like the stock light when finished

My parts list:
2 Batteryspace RCR123A's
T bin Luxeon III Star
1000mA BuckPuck
Luxeon Lens Holder
15 Degree Lens
Slide switch
Charging Plug
Video card heat sink
Misc parts from a plastic Harrier model

Here is the documented buildup:

Behold! The Planet Bike Dual-Spot light.


The AA caddy and the case opened


The stock internals


Exploded view of the new lighting assembly


I had to fit that black lens mount into that reflector


Dremel to the rescue!


The holder and lens fitted


In addition to the new lens, I had to use the original integrated cover/lens because it was part of the mounting design. Also, it keeps the light looking 'stock'.


I took 1/2 of a nose cone from a Harrier airplane model that was laying around and molded it to the top of the case. This is the hot air exhaust for my heatsink design.


This is the rear view of that exhaust


Using part of the Harrier canopy, I made an air intake scoop.


Another view of the intake scoop


This is what the case looks like put together. Air enters from underneath, flows over the heatsink, and out the top vent.


I mounted the RCR123A's this way and added a slide switch to the battery cover. I used a slide switch because of the limited amount of space.


View of the switch with the battery cover on. This cover will be closed with epoxy later.


The parts were painted flat black and flat grey.


Here is the recharging jack. It was screwed into the case by a few threads and then glued in with 5-min epoxy.


Almost done! The heatsink was mounted to the Lux with Arctic Alumina Thermal Epoxy. The case was sanded again with 600grit and a 2nd coat of paint applied.


The 1000mA BuckPuck being wired up and mounted with hot glue.


Ta da! All done!


Rear view. I really like that charging jack.


Mounted on the bike. The blue dot you see is the back of the black anodized heatsink.


Here is my charging setup


How it was mounted in my testing box. Since this light is meant to be used on a moving bike, I had to mount a fan in front of it to get airflow over the heatsink.


Unit fired up before closing the lid to start logging


BEFORE MOD - Shutter 1/2 f 3.5


AFTER MOD - Shutter 1/60 f 5.6 I think this picture is deceiving. Since the light was so spread out and intense, the camera changed the shutter/aperture to prevent it from being blown out. This made the Before and After look almost the same. Trust me, the after was MUCH brighter.

Hallway shot. This is a better representation of the output. There is no way a single 5mm white led can throw this!


And the runtime plot. X=Minutes Y=Measured Output (mA)


After hours of grinding, cutting, and sanding, I feel that I met and exceeded most of my criteria so I'd call this mod a success!

I was surprised to get 50 minutes of regulated output from it. I charged the light after it cooled and it took 131 minutes @ .15A. I may just send this over to the folks at Planet Bike in hopes of free stickers or something.

edit: I had a chance to ride around the neighborhood tonight and am very happy with the light. The 15 degree lens evenly lights up a good portion of the landscape in front of me. I think it's much easier on the eyes because there isn't a hotspot for an object to suddenly appear and then disappear in the darkness as you run it over. I posted beamshots in a response below.

All comments and/or criticism are welcome!

[greenLED]

dude, you're nuts! I love it, neat work.

[LumenHound]

That's a terrific mod!

How much $$ and when will you begin production??

[bruner]

Arkayne,

Beautiful workmanship!

The use of an air intake was unexpected, very smart.

Good work

Thanks for sharing too.

Dan

[sortafast]

sweet light mod, and good choice on the headset. Never really thought of modding a light like that. BTW how much better than stock is it at illuminating the road ahead of you? I am in the process of getting started on building my first light using a LuxIII. I think that i want to eventually build up a helmet light using 1 or 2 Lux V's to mount on the Full face for some summer time night DH'ing.

[Arkayne]

That's a terrific mod!

How much $$ and when will you begin production??

Thx! I tallied up the damage to my wallet and here is the rundown:

2 Batteryspace RCR123A's $25.99 (Package deal with 4 batts and charger)
T bin Luxeon III Star $14.95
1000mA BuckPuck $19.95
Luxeon Lens Holder $.40
15 Degree Lens $2.10
Slide switch $.75
Charging Plug $.75

Jeeebus, I spent about $65 on this thing! I had no idea. The damn light cost me about $25 too. Oh well, it was worth the learning experience. Maybe it's time to buy a lathe?

[Arkayne]

BTW how much better than stock is it at illuminating the road ahead of you? I am in the process of getting started on building my first light using a LuxIII. I think that i want to eventually build up a helmet light using 1 or 2 Lux V's to mount on the Full face for some summer time night DH'ing.

For night DH I'd only use HID. heheh I guess I've become spoiled like that. The leds just can't compare to the raw power of hid. Unless, you had a whole row of Lux V's on your bars AND helmet rally-car style.

I'd compare the stock beam to a semi-focused 2AA Mag. It wasn't very good to begin with. Here are some comparison shots I just took:

No lights on


Surefire A2 held above and behind the handlebars


XM-2 Lux III held above and behind the handlebars


My modded light bar mounted. Notice that the construction in the distance is visible now!


Here are beamshots against a cement wall 15ft away:

A2


XM-2


My modded light


This is a 15 degree lens and it really lights up the landscape. I have a 5 degree that I'll pop in later for comparison sake.

[CQB]

(*thud*)

that was the sound of my jaw hitting the ground. =)

as i expected, a most excllent mod, Arkayne!

... and guys, he IS nuts! A personal friend that I can attest to for his... "nut-ness".... dont know if i like the sound of that afterall....?!? =P


keep going at this rate and you'll soon be quitting your job to sell lights out of your apt!! Hoo-Yah! (*proud smile*)

[Timson]

Absolutely brilliant

Love the way it looks completely stock apart from the subtle intake / exhausts...Which have been integrated beautifully I might add.

A real wolf in sheeps clothing...Should turn a few heads out on the road.

So what about the cost......The point is you've created something unique and special which is a top quality job - not a bodge up - and well worth it in my book. Congrats.


Tim.

[sortafast]

Thanks for the headlight shots that really helps me. but, still sweet job. I hear yah on the HID, but the $3-400 wholsale for one is a little less than appealing to me. I would have a hard time dhing with one because knowing my luck i would probably stack it coming off a drop or something and rip the thing right off. For right now my 20w night hawk gets things done OK. I think that i want to build a good helmet light, maybe make a 2 lamp set up or something. hopefully my leds get here today so i can start tinkering. btw What did you use to affix the vents you made to the light body?

[Arkayne]

Thx for the positive comments guys!

Sorta: I attached the plastic pieces with 5-min epoxy and then molded it to the case with plastic modeling putty. Once dried, it was fairly easy to sand down to blend with the case.

I think this guy's dual lux v custom build is what you are looking for!
http://www.candlepowerforums.com/vb/...d.php?t=100849

[sortafast]

mantastic, that was just what i am looking for. If mine come out the way i want them to, it should be real killer, and hopefully cost less than $100 if i can do things right. putting the wife through nursing school on a bike shop employee's salary is not too friendly to purchasing much in the way of toys. Still trying to figure out how to do this and buy a new kona frame. gonna have to start strippin again

[carrot]

How the heck did I miss this? It's awesome! I especially love the air scoops.

[marcolino]

Wow!!! nicely made! i love the scoops, they´re functional and aesthetical!!!

Great instructable!!!

Congrats!

[msxtr]

I'm like it, excellent job. Are enought that heatsink for the leds??

Greetings - Saludos

msxtr

[Krit]

Very good case. I like air flow concept.

[Essexman]

Best mod I've seen in ages. Your attention to detail is very high. I'm looking across the room at my catseye bike light and wondering what's possible. Thanks for sharing your work.
BTW - you missed a very important part out, what did your girlfriend think of the new light??

[Calina]

This thread is a year old but I hadn't seen it before. Impressive mod!

Imagine how a Cree or Seoul LED would throw like.

[joedm]

Hey maybe even throw in another led up the top in the empty space...
looks like the reflector in there could take one.

[Darell]

Thanks to whomever dragged this back up! I hadn't seen it either, and am very impressed! If only they'd make these lights right the first time! finding a good donor body/mount is the hardest part. I like the AA-123 conversion. Hell, I like it all!

[AndyTiedye]

Maybe someone found it in here, which is the start towards
turning Bike Light Thread Links into a real index.

[Nubo]

The question that was never answered:

How did the GF like it???

[Bandgap]

That is a lovely looking light, and nice to see so much care in a build.

I tried to make an air scoop bike light based on the look of the front end of a Supermarine Spitfire.

Sadly I discovered that I didn't have the artistic skill, and casting aluminium was much harder than casting lead or brass.

Steve

[Bimmerboy]

Glad this was brought back from the dead because I never saw it either. Totally ingenious mod in every way, Arkayne!

[Arkayne]

It's alive! The darn thing still works!

I used it heavily for the first few months during my work commutes and then it's been off and on. It's been relegated to stroller/bike trailer duty as of late. Regardless, the little light that could.... can. And still does.

It has been rained on, splattered with mud and been down some bumpy downhill trails without falling apart.

[wildwood]

Bet youre well happy Arkayne. Bet its more than paid for itself by now.
Time to do a XPE/XPG mod