space between optic and its housing

[4thpage]

Hey, folks! I like this heat sink http://www.maxxprod.com/mpi/mpi-29b.html for the optics/LED housing in my dual MC-E light (a la Allen's copperhead http://bikeled.org/copperhead/Copperhead.html). My optics have an OD of 21.6mm, and the ID of the nearest-size heat sink is 28mm.

My question: purely in consideration of strength and holding everything together, is it necessary to try to close this gap somehow, or will fixing my MC-E stars to the body of the light with AAA and the optic holder with epoxy be enough to hold them securely?

I'd thought about trying to fix some sort of 1/8-inch rods or something on 4 or 5 points between the optic holder and the housing. This could also be useful in fixing a lense over the optic. I'm using one LM1-RS and one LM1-REC.

Opinions/advice?

 

[znomit]

I always bond the optics to the stars, nothing else.

 

[kuksul08]

I had a similar case with the ledil square optics and 1" square Al tubing. I wrapped electrical tape around the optic to close the gap, then packed silicone around it to hold it against the LED. You are dealing with a much bigger gap it seems, but the concept is similar.

 

[BrianMc]

This builder:

http://www.racedaynutrition.com/features/bikelight.aspx

Used pipe caps in the heat sinks and the optics look pretty tight. The caps are not light, but help heat management. Thought you'd like to see this, in case you hadn't run across it.