Who needs XP-G bike lights anyway? I've got..

Joined
Sep 24, 2008
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649
Location
Boston
2 Nichia® Rigel LEDs putting out over 46 lumens!

Foreword,
The following article is about bike lights used to be seen NOT to illuminate any kind of off road path. Visibility was the number one concern in the making of these lights.


Don't get me wrong I'm a flashaholic, I've XP-Gs on the way for all kinds of mods. My beloved girlfriend needs a bike light and has been asking for one for a long time. She is NOT in any way interested in amazing output LEDs lights, she also has minimal interest in maintenance of any light emitting device :). I looked around for some LEDs to send off into the cold and wet most likely to their demise. One of the big issues as I see it with bike lights in the $20-$100 range is that the mounts to the bike are weak. In the middle of winter they become more brittle and prone to break. Bike lights also have a way of walking away on college campuses as well. For these reasons I've decided to make up a low cost decent performance light setup.

The plan is to mount the LED permanently to the handle bar area and place the battery box near. This was made with parts I had sitting around so the driver is not ideal but works. It is a micro puck I purchased a while ago from LEDsupply. The LEDs are from there as well, good for hobby lighting. I am still working on some type of weather resistant small enclosure for the batteries that I plan on mounting close to the headset. Any input for low cost enclosures would be appreciated as well as a switch that can live outside.

I still need to clean up the edges but I plan on leaving this as a low profile item so as to not attract attention to it's self. The epoxy is just 5 minute stuff from the hardware store. To make this beauty of a protective layer I wrapped the light in electrical tape and poured the pre mixed epoxy onto it then let it set. The mounting surface is just Aluminum stripping from the big box store, it makes a great "test area" for LED projects. Tips for doing this again (and I will be repeating this process for the rear red lamp) spend time on masking the area to be epoxied, this will make it less ugly and save sanding time. I'll post updates as this project goes forward. All comments are welcome.




 
What kind of batteries are you intending to use? IIRC micropuck is boost yes? So 2 AA? If you use a small plastic project box the lids will flex enough to activate a decent microswitch positioned properly (ala superflash) I'd be tempted with a project box with a single 18650 (microswitch inside) then you can put a gland in for cable to the light, driver will fit in there, you can even pot it if you want. Use a dummy cell attached to some cables to charge, or butcher a lion charger.

Bobs your uncle, hell, if you pick your housing right you can't mount the LED on it & you don't need any wires.
 
Just a thought. Why not use 4xAA's in some project box with a waterproof detachable cable that is zip-tied or velcroed to her bike. That way when she's off her bike all she needs to carry is the battery pack only and because it is 4xAA it is easy for her to charge the cells in a battery charger at home or away/travel.

Also I'm interested in seeing how the finished item looks like. I know girls are always fussy about looks. :poke::shakehead:sssh::laughing:
 
Another thing is if you plan on perm mounting this to her bike perhaps using 4 screws then 2 when mounting. Use 2-3 security screws or all 4 different security screws and types and give her a U-lock & cable/chain lock so she'll see that bike when she comes back out.
 
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