Low Cost Bike Light Construction

Found some time today to finally get started on a head lamp for my helmet.

Its a fairly simple build this one with most of the parts being unmodified.

Below you can see the 8xAA battery holder (4 on top, 4 below), the LED driver in the middle of being mod’ed to be adjustable and the mounted XP-G LED and optics on the right.

Elec components

Just like the trike lights, the LED is thermal glued to a section of U shaped aluminium that is inserted into a section of box shaped aluminium. The optics sit forward of the LED and the LED driver sits just behind it.

This is the body of the light coming together.

bodyIts hard to make out at this angle, but the bottom of the image is the front of the light. The hole is for the 4 position on/off/brightness knob. The side sections will wrap around it and connect to the base.

It should be more clear when its all finished off in a couple of days.

Then there will be lots of photos to follow.

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About Richard

I am a Materials Engineering working in the field of Magnetic Materials in Melbourne, Australia. This blog covers my personal interest in all things CNC.
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