The lowdown: 3 luxeon III (TV1J) in series with an nFlex driver using a 14.4v NIMH drill battery. Optics are carclo 26.5mm. Optics holders are turned from PVC pipe. Stars are thermal epoxied to the heatsink. Holders are turned to be snug fit around stars.
Basically a fancy cup with a ledge for the heatsink to sit on. Used computer heatsink compound so I could get to the driver if I needed to.
The white bits are lengths of PVC used to fill space from bezel to heatsink as the optics sit a bit back of the bezel. I had originally intended to use 2 30mm optics and 1 26.5mm, but found the 3 did just as well with less fuss to fit. on the back are a momentary switch to control the driver, a DC jack (N size if I remember right) and the bracket to fit to my handlebars to match one I already had.
I tried to show the bevel on the heatsink for the bottom emitter. I think it's about 10 degrees if I remember my trig right. It points it down to light the road more immediately in front of me. If I had to do it again (and I will) I wouldn't make the angle quite so large, as it is too small and bright a hotspot to be as useful as I thought, but I still think it's a good idea. I can say that because I took the idea from one of the posts discussing bike lights here!
For the record, I'm exclusively a road rider. I think the beveled heatsink I made would be very effective for offroad, but I can only guess since I have no experience in the dirt.
For winter riding, the cooling fins are definately overkill. On my hour and a half rides, continuously on the 1 amp setting, the light is COLD to the touch in 40-50 degree temps. I will update in the summer if I need to.
Cut the glass for the bezel from a broken window 3/32 inch thick. Finish is plain old Kan o' Krylon. Tried to anodize it... disasterous to say the least. Plus I don't want it to be too tempting for thieves...
This has been a very rewarding project for me. I bought a 7x12 mini-lathe to do this project. I'm pretty pleased with the results especially for my first metal turning project. Took me 2 weeks to complete in the evenings after work, and I learned a lot doing it!
Forgot to mention, obviously "borrowed" most of my inspiration from ElectroLumens' (or is it Elektro?) design. Aside from the pure joy of DIY, I wanted a closed in back. If I had to do over again I would buy his and mod it. WAY cheaper!!! I don't see how he could do it that cheap!! I think his design has changed since I started mine, even. Oh, if only I had waited!!
/shameless plug off/
Basically a fancy cup with a ledge for the heatsink to sit on. Used computer heatsink compound so I could get to the driver if I needed to.
The white bits are lengths of PVC used to fill space from bezel to heatsink as the optics sit a bit back of the bezel. I had originally intended to use 2 30mm optics and 1 26.5mm, but found the 3 did just as well with less fuss to fit. on the back are a momentary switch to control the driver, a DC jack (N size if I remember right) and the bracket to fit to my handlebars to match one I already had.
I tried to show the bevel on the heatsink for the bottom emitter. I think it's about 10 degrees if I remember my trig right. It points it down to light the road more immediately in front of me. If I had to do it again (and I will) I wouldn't make the angle quite so large, as it is too small and bright a hotspot to be as useful as I thought, but I still think it's a good idea. I can say that because I took the idea from one of the posts discussing bike lights here!
For the record, I'm exclusively a road rider. I think the beveled heatsink I made would be very effective for offroad, but I can only guess since I have no experience in the dirt.
For winter riding, the cooling fins are definately overkill. On my hour and a half rides, continuously on the 1 amp setting, the light is COLD to the touch in 40-50 degree temps. I will update in the summer if I need to.
Cut the glass for the bezel from a broken window 3/32 inch thick. Finish is plain old Kan o' Krylon. Tried to anodize it... disasterous to say the least. Plus I don't want it to be too tempting for thieves...
This has been a very rewarding project for me. I bought a 7x12 mini-lathe to do this project. I'm pretty pleased with the results especially for my first metal turning project. Took me 2 weeks to complete in the evenings after work, and I learned a lot doing it!
Forgot to mention, obviously "borrowed" most of my inspiration from ElectroLumens' (or is it Elektro?) design. Aside from the pure joy of DIY, I wanted a closed in back. If I had to do over again I would buy his and mod it. WAY cheaper!!! I don't see how he could do it that cheap!! I think his design has changed since I started mine, even. Oh, if only I had waited!!
/shameless plug off/
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