Look what I found.
Its a curtain rail.
Its a little to narrow to fit leds inside, unless you do a little grinding. 17mm stars from Cutter need a little shaved off with the grinder. Q5s because they didn't have R2s last week. Boo. But my thursday order arrived on tuesday.
Its a little too short to fit an optic in, unless you get some of those tiny little polymer optics. Its a perfect fit. About a mm on the sides and the top. Looks like it was made for it. I have found two almost identical rails, so I think its a standard sizing. Probably you can find end caps too. I haven't looked.
Three is a good number. Two wide and one narrow optic for the MTB.
File some curves to let the light out a little. A little glowinc glow in the dark magic paint on the inside too.
Might get a bit warm in there. How about some air scoops on the side.
Took a few extra cuts and a little bending. The main body is only 6cm wide. Thats over 100lm/cm. I have about 4m of curtain rail. Anyone need a 40,000lm light?
Add some exhaust holes in the back, and a hole for a mount. Forced air cooling should keep 12w under control. Cool running. One piece housing means no junctions keeping the ergs in. The Aluminium is 1mm so easy to cut and file.
LEDs are sitting on thermal paste and glued in place with araldite. Holes drilled through the mounting plate for the wires at each end. I had to cut away some of the optic mounts to solder in the wires. These optics need the stars with 6 pads. DX or Kai do Q5s on tiny stars which would eliminate the grinding step.
Need to seal up the front, sides and the gaps in the scoops and wire into my old bflex/battery then I'm out on the trails again. More pics when finished.
New bflex is waiting for inspiration for a mount. Anybody have any ideas?
Oh, and I have another housing made for dual helmet light. Might finish that this weekend. Its something different again.
Top marks for Cutter, Taskled and glowinc. All delivering to NZ in under a week.