LED Bicycle lights

LED bicyle light projects & info for the do-it-yourself set....

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DIY Lights

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Technical Info

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Design Goals for DIY Light

I'd like to build a light similar to the Dinotte 3w (single emitter powered by 4-AA NiMH battery). I think I can clone this light (using a Cree XR-E for better output) for around the same cost as the Dinotte, or slightly less. Or, I'd like to build a two-LED version of the Dinotte. I'd like to keep the battery pack constrained to 8-AA 2500mAh NiMH cells -- either configured in series for 9.6V or in two parallel sets of 4-AA each for 4.8V; this is to keep battery costs low, to leverage existing NiMH cells and chargers I already have, to keep the battery lightweight and compact, and to allow easy battery changes as cell-technology improves.

Tentative Parts List for Light

LED(s)purchased
(2) Cree XR-E (P4 bin)
Opticspurchased
(2) L2 Optics OPTX 1-006 Lenses - one 8-degree diffuser and one 8x25-degree diffuser
Power Driverpurchased
TaskLED bFlex with bicycle-specific UI (buck) or MaxFlex (boost) bicycle-specific UI due out later this week
Thermal Adhesivepurchased
Arctic Silver Alumina Adhesive (2 Part Epoxy) and Arctic Silver Ceramique (I plan to use the Adhesive to bond several metal washers or other bits together to make a heat-sink slug, and also to then bond that to whatever housing I figure out. The Ceramique I'll use for thermal conductance away from the LEDs to the slug/housing; I'm going to try to screw the LED to the slug vs. permanently bonding it.)
Battery/Chargerpurchased
CH-V3150 Fast Smart Charger (2 hrs 4 Channels 110-240V ) + 8 AA 2500mah NiMH Batteries with 2 holders (will use my existing 4-AA NiMH charger as well) plus (1) Battery holder: 8 x AA Battery Holder With 6" Wire Leads and/or (2) Battery holder: 4 x AA Battery Holder With 6" Wire Leads
Handlebar Mounting Clamppurchased
Handlebar clamp
Motor Heatsink for Light Housing?
Google Image Search
Source for Aluminum Tubing, etc.
Smallparts.com
Onlinemetals.com
Wicksaircraft.com
Aircraftspruce.com
Misc
Drill and Tap Size Chart
ANSI Screw and Nut Threads Size Chart
Tap Drills for Number Machine Screws

Dual Cree XR-E Light -- Finished!

Dual Cree XR-E Bicycle Headlamp
Originally uploaded by jimgskoop.