mini mag aa bicycle light mod

[henry9419]

ive been in need of a dedicated bike light so i think ive come across a good solution. my original idea was to find someone to mill me a completely original housing but then i realized that one it would be too expensive and two it would be alot cheaper to get a few old incandescent mini mags and put a single XM-L or a triple XP-G in each (have 2 total on bars) and have them wired to a single battery pack and switch and then make a single one for a helmet light. eventually i also want to upgrade the buld in my led version as well for general usage. anyway here ill post pics as i get parts and ill ask questions about the build. so to start this off what would be the best way to wire the driver to two separate leds in separate housings? im working a a hand drawing of what i want it to look like when completed and the hopefully tomorrow ill be able to post that if i have it completed by then.

 

[rayman]

I had that idea of a bike-light made out of a MiniMag for quite a while and all parts are lying in my shop waiting to be build together ;). My idea is to cut the Maglite down that you can just place a driver in the battery compartment and glue the XR-E on a copper heatsink which was sold some month ago here on CPF. The only thing about which I'm not really sure is how to fix the light to the handlebar so it can be easily removed.

Regarding your idea I doubt that the surface of the MiniMag is enough to cold down the XM-L or triple XP-G. I modded a D-Maglite a while ago to be used as a bike-light, I would consider this too.

rayman

 

[henry9419]

im thinking of butchering a few reflector mounts or using a couple of the twofish lockblocks or something similar and in terms or cooling i was thinking maybe getting a c or d head and making a reducer to fit on the mini or mounting a heatsink across the two lights and then i would hope the air movement would be enough

also im not sure of what driver im gonna use that will fit in the mini aa body...maybe a bucktoot or whatever it is or a regular buckpuck if it will fit....

 

[henry9419]

well i have most of the heatsink designed and once its finished in sketchup ill post pics of it...it should be easy enough to machine with the tools i have availible

 

[henry9419]

well thats my sketchup drawing of what the outside will look like so far except for the head of the light...so pretty much a mag lite except shortened my plan is for it to be around 70mm in length but thats measuring off of a newer led version but i know that the incandescent one has a slightly shorter head so in the final version it will be shorter. now im gonna draw my design for the AA to c/d head adapter just in case im gonna go that route and im also gonna make the heat sink/pill whatever you call it for the heat transfer of the driver and led to the case and any external heat sink that i make

 

[henry9419]

top view

bottom view-driver will go in the round hole in the bottom part

today in school i had an even simpler idea but first i need more exact dimensions of the c lights head

 

[post tenebras]

Dkg makes an awesome, solid, CNC minimag mount. Google DKG mini mount.