Building my own drop in units...

[redswr]

hi folks i was gonna put this in the transportation but it's more of a building thread so i thought it'd be better suited here, I ride/race dirt bikes and some races are at night. Theres a lot of HID upgrades but they require you to upgrade the stator to produce more power and are generally pretty big and look ugly. What i'm wanting to do is replace the standard single bulb with a LED spot in the middle with some smaller floods off to the sides.

heres what i'm working with (every bit of it's plastic too)

My tech questions:

#1 i was thinking about using the stock assembly but forming plastic on the inside for each of the 3 LED's, it's got to be something easy to bolt in place aka "drop in" to the stock mount (piece where #1 points to)... think it will get to hot? what can i use to make the plastic reflective? the redneck in me said aluminum foil or spray it with okie chrome...lol.

#2 one thing i've been looking into for my bike is a way to keep an energy reserve because when the bike stalls (either in a crash or just bad riding) the light turns off... i want some way to keep the light on for ~ 1min so i can get back to my bike.

 

[redswr]

i'm over thinking a lot right now about stuff... if you've got an answer to #2 let me know... #1 i'm working out in my head but i'm thinking an all aluminum assembly is neccesary and probably not to hard to build. What driver would i need for (2) 3-Up XP-E Indus Star's and do you think that would be enough to light up enough space while pushing 90mph?

 

[Slickseth]

How many lumens is the stock bulb?
If you want to make as much or more light than the stock setup, you will need to mount the emitters to a thick aluminum or copper heatsink.
I don't recommend attempting to form a reflector out of plastic and aluminum foil. It will be much worse than the thing that you were trying to "upgrade".
You can purchase machined aluminum reflectors specifically shaped for the emitter that you are using. I think I would use a combination of flood and throw reflectors.
As for power consumption, you will likely end up in the 10W-30W range, but with (at least) the same amount of light output as stock.

 

[precisionworks]

I'm thinking an all aluminum assembly is necessary

A more effective approach would be to use copper as a heat spreader/heat sink for the LED, then bond the copper to an aluminum shell.

probably not too hard to build.

Right :devil:

Easier to build than the Space Shuttle ... certainly. Less costly ... probably not, unless you do all the machining yourself.

you will likely end up in the 10W-30W range, but with (at least) the same amount of light output as stock.

You may be correct, but it wouldn't surprise me if 60w-75w is needed for adequate illumination.

a way to keep an energy reserve because when the bike stalls (either in a crash or just bad riding) the light turns off... i want some way to keep the light on for ~ 1min

That part IS easy. Make up a battery pack, most likely a number of 18650's, with a sensor or relay that brings the 18650's online when there is no alternator output BUT the key is still in the on position. The same relay would disconnect the battery pack when alternator voltage was again sensed.

 

[redswr]

ok found out that the stock is 130W/12V... is that gonna blow most LEDs?

 

[precisionworks]

the stock is 130W/12V... is that gonna blow most LEDs?

If you run each LED at 10w, you need 13 to produce 130 watts. The electronic guys can verify this, but I believe you'll also need 13 driver boards.

My earlier statement Easier to build than the Space Shuttle no longer applies :)

 

[redswr]

If you run each LED at 10w, you need 13 to produce 130 watts. The electronic guys can verify this, but I believe you'll also need 13 driver boards.

My earlier statement Easier to build than the Space Shuttle no longer applies :)

geez...lol maybe a regulator? i know about volts but havn't really had to much dealing with figuring out watts