Triple cree XPE ready to machine

[brad72]

After much procrastination and reading hundreds of posts i have drawn my handlebar light up ready to be machined together with a helmet light this weekend...hopefully. She is a triple xpe dirven by a 700ma buckpuck and 14,8v lipo. The switches are on/off, and a low/medium/high that can be adjusted by 5k variable micro resistors. Still wondering if I just direct drive teh light fomr the battery just in case the on/ff switch gets bumpted .

I have added a clear panel on the botton of the lamp to send some of the wasted light down onto the front wheel. This housing has a swivel mount connected to the bar clamp with a M4 countersunk bolt. The hood over the lens should stop glare when standing and pedaling and the underside will be polished to a mirror finish to throw more light down, i hope. The helmet mount will not have the hood and will have a tilt mount.

Hopefully there are enough fins to keep here cool but will just have to make it and see what happens. All up the light should weight 88grams and measures 65 long x 35w x30h. Heres a couple of cad pictures but will post some more photo's when i finish the lights.

 

[Linger]

Re: Triple XP-E ready to machine

I like the clear bottom, and reflector that projects at the top (also shields face from rain)

 

[thysmeades]

Re: Triple XP-E ready to machine

very nice looking light, I think it's gonna be more difficult to make than it was to draw. What program did you use? good luck

 

[brad72]

Re: Triple XP-E ready to machine

Thanks guys. The program used is autodesk inventor. Your right about the machining though. It took a couple of hours to design to tweak. Machining on the mill is going to be a bit more time consuming though. Just have to flood with coolant and up the spindle speed.

I was going to use round bar to make it which would be really quick to machine on the lathe but I'm a glutten for punishment and wanted something different.

Really looking forward to getting on the mill. I think my wife has other idea's for me this weekend though. :sigh:

 

[brad72]

Re: Triple Cree XP-E ready to machine

Well managed to get the bar and helmet bodies partially machined thisafternoon. Man i wish i had a cnc. Hopefully will get both finished tomorrow. I have already wired the Xpe's and can't believe how bright they are. Even houses 150 meters away are being lit up and that is with only 1 lamp. Having both on is going to awsome out on the trails.

 

[Steve K]

Re: Triple Cree XP-E ready to machine

Fun project! It's going to look soooo much more professional than my projects. A hand drill and a hacksaw can only do so much <sigh>.

My only comment regards the apeture that lets light shine out the bottom. My experience is that I'm not too concerned with what's a foot in front of me, and care more about what is 40 to 100 feet ahead. Plus, that might put enough light close to you that it affects your night vision. Fortunately, it should be easy enough to put some tape over it to see if it really is a problem. If it is, it would be easy enough to epoxy a plug into the hole (and no one would see it, since it's on the bottom)

have fun!

Steve K.

 

[Linger]

Re: Triple Cree XP-E ready to machine

Plus, that might put enough light close to you that it affects your night vision.QUOTE]

Oops. If you had noticed the post above yours where OP writes that he already has the emitters wired together and how bright they are lighting up a house a 150m, then perhaps we'd agree the little spill at the bottom isn't going to wreck dark addapted eyes.

I do agree with you that most riding is concerned with things farther ahead. Which is where the majority is aimed, wisely enough. A little spilt on the ground in front might be helpful when stopped, to tie shoes, check air pressure.
I have a Cateye 1600 (rechargable) with a clear case. So wires and batteries are visible, even illuminated when I turn the light on.
I totally love the clear case, and if i could I'd use it for all my bike lights. The reflector (or optic) still throws most of the lumens where you want them, and the brilliance of the clear case is that all the 'waste' lumens are freed and become mucho helpful in making me visible.
I vote keep the clear.

-Linger

 

[trout]

Re: Triple XP-E ready to machine

Dead nice that light Brad and a very cool concept there is a whole load of lumens that never make it out the optic so why waste them

I put this thread up a while ago about the subject http://www.candlepowerforums.com/vb/showthread.php?t=238266

 

[brad72]

Re: Triple XP-E ready to machine

Thanks for the advice guy's. You know I hadn't even thought about my night vision with too much light shining onto the front wheel. Will have to see how that one goes and can always replace the polycarbonate with a bit of alloy if a problem.

Hey Trout, is that light you have linked to the same as the kit on the cutter site. That is 1 bright little unit and I like the idea of the mixed optics.

 

[Jonster]

Re: Triple XP-E ready to machine

Very nice.
I'll be interested to see the finished article!

 

[znomit]

Re: Triple Cree XP-E ready to machine

Plus, that might put enough light close to you that it affects your night vision.

Oops. If you had noticed the post above yours where OP writes that he already has the emitters wired together and how bright they are lighting up a house a 150m, then perhaps we'd agree the little spill at the bottom isn't going to wreck dark addapted eyes.

The spill directly down can be significantly bright. Your eyes adapt to the brightest part of the beam, with a really bright hot spot its harder to see whats in the spill, but yeah some tape will solve that if its an issue. I'm more worried about the solid section creating a dark band.

ps, OP nice work.

 

[brad72]

Re: Triple XP-E ready to machine

Hi znomit, the idea behind the reflective hood over the light was try and stop the handlebar light annoying oncoming traffic on the road rides (theory anyway). I was planning to make another one for all mountain biking but again will see how it it goes. I'll post some beam shots when finished. They never lie.

Of to work now to finish her up

 

[znomit]

Re: Triple XP-E ready to machine

Hi znomit, the idea behind the reflective hood over the light was try and stop the handlebar light annoying oncoming traffic on the road rides (theory anyway). I was planning to make another one for all mountain biking but again will see how it it goes. I'll post some beam shots when finished. They never lie.

Of to work now to finish her up

I was meaning at the bottom of the circle, I'd leave it open like Troutie is doing.
You need quite a long hood at the top to block the light from pointing into drivers eyes.
You using a QR cateye spacer on the mount?

 

[trout]

Re: Triple XP-E ready to machine

Thanks for the advice guy's. You know I hadn't even thought about my night vision with too much light shining onto the front wheel. Will have to see how that one goes and can always replace the polycarbonate with a bit of alloy if a problem.

Hey Trout, is that light you have linked to the same as the kit on the cutter site. That is 1 bright little unit and I like the idea of the mixed optics.

Brad72 The linked to light is the newer brother to the one on the cutter site and is currently being tidied up a bit whilst waiting for the XPG leds to put in it

have a look here for some pics of it being born http://s199.photobucket.com/albums/aa46/amticoman/LIBERATOR/

 

[brad72]

Re: Triple XP-E ready to machine

Wow trout that a sweet looking light. Well done. Wouldn't it be nice to have your own cnc in the back shed. How does it go for heat with the 6 leds? Thermally the housing looks excellent and with the black anodising the emissivity would be greatly improved when going slow up hills. I only ask as I will do some heat tests today but unsure how warm the housing should get driving all leds @700ma in both still and moving air.

I just love seeing objects come to life from a 2 dimensional drawing.

 

[trout]

Re: Triple XP-E ready to machine

Brad72

Thanks it is sweet and dont worry about the down spill with yours you wont notice it when riding except when you need to look down and can see the wire about to wrap around the front wheel . or the snake .

Though Znomits right about a possible shadow as mine creats them off the cables a bit but suck it and see .

No problems heat wise with mine but I am in the UK with lower ambients

Took it out tonight while walking the dog it has xpes in at the moment and ran it on full whack it took 25 mins before the heat dimmed the Maxflex and the dog loved it for spotting the rabbits to chase .

silly bugger never gets one though

 

[brad72]

Re: Triple XP-E ready to machine

My dog also loves going out in the dark with any kind of light.

so will the xpg's run cooller as they can put out more light with less current draw?

 

[brad72]

Re: Triple Cree XP-E ready to machine

Well i got the handlebar light finished bar the switches on the rear of the housing. It has only been undercoated so will hopefully look better when painted properly. Was certainly a fidly little bugger to make. Total weight is 98grams. Heat wise, sitting in still ambient air @ 18 degrees C the lamp on full power (700ma) leveled out at 45 degrees C. I would have liked to of seen it a bit colder than this but i'm sure once out on the trail the temp will drop. I also need to bevel the front face a bit more as it limits the beam throw to the sides. The pollished underside of the hood does reflect a few more lumens down to the ground and diffinately stops the glare when standing over the bars. Other than a few tweaks needed I'm pretty happy with my first attemt. Just need to finish the helmet lamp and get the batteries completed then hit the trails. Heres a couple of picks. (connection between the lamp and bar mount is temporary and only for the sake of the photo)

 

[DimeRazorback]

Re: Triple Cree XP-E ready to machine

Excellent work!

:twothumbs

 

[thysmeades]

Re: Triple XP-E ready to machine

well done! looks great. Can't wait for the beam shots
Thys