DIY Cree LED bike light

[Marius]

The "little" one on my head!!! hiehiehie - That one puts out about 720 Lemons or what ever, how many lemons can ML's make???

[mountain_lion]

 

Nice going ML!!! HOW MUCH did it cost to build the two brighter lightes?/ Lilo needs a bright light but at a affordable price you see's.

 

I will post some prices later.

 

However be warned that building your own light is not worth it from cost point of view if you calculate the time spent. It takes many hours...

 

Many parts used were from "scrap" that my dad and myself had collected over the years.

You also need a nice workshop.

My dad has a very well equipped garage and all the wet weather in the Cape over the last few weeks gave me a good excuse to spend some time with him. We had loads of fun playing with the lathe and pondering over several design options...

 

 

 

[straatvark]

Well done ML!

 

 

 

you need to mow your lawn...

he is drying it first with the lights

[mountain_lion]

 

The "little" one on my head!!! hiehiehie - That one puts out about 720 Lemons or what ever' date=' how many lemons can ML's make???[/quote']

 

Notice the lemon tree in the photos?

Just count the lemons on the tree and you will know.

 

Marius, I think you should order your light from Brighter-lights...

 

[Marius]

ML, if you think I will actually attempt to build my own light you don't know me very well. Only two plats on my stove work, if it can't be fixed by flipping the main switch it's going to stay broken.

[IanJ]

ML are you intending to make this available as a kit? I don't mind doing my own assembly etc. but don't have the time and resources to source components and manufacture the hardware.

 

If you are prepared to make up the machined parts and sell it as a kit and if the price is reasonable I would be interested in 2.

[markStockton]

 

However be warned that building your own light is not worth it from cost point of view if you calculate the time spent. It takes many hours...

 

Yes, but it is good fun.

 

[mountain_lion]

 

ML are you intending to make this available as a kit? I don't mind doing my own assembly etc. but don't have the time and resources to source components and manufacture the hardware.

 

If you are prepared to make up the machined parts and sell it as a kit and if the price is reasonable I would be interested in 2.

 

Sorry, parts list with possible sources I will post (will try to do it tomorrow), but as already said it takes way to much time to do for others.

The fun is in making your own for personal use. After that, it becomes work and my day job pays much better.

Speaking of which, I must get back to work...

 

 

[mountain_lion]

 

 

brass endcaps?nice thinking. are they for plumbing' date=' and can you get an o-ring in there to seal them?

 

[/quote']

 

Yes, standard plumbing fitting available from any reputable hardware store.

(also called stop ends).

 

I guess you could try to find an O-ring which will fit.

I cut some circular pieces out of clear plastic packaging (everything comes in it these days) to cover the lenses. You will notice that the lens holders have small openings around the sides. These need to be at least covered to keep dust etc. out.

The holes at the back for the wiring are sealed with silicone.

 

mountain_lion2008-09-24 11:12:12

[mountain_lion]

 

 

Very' date=' very, very nice. I think it is time to upgrade my light. Where did you get the LED's and lenses? Did you use the same Buckpuk?

[/quote']

 

You can order from the Chinese sites (e.g. Kaidomain or Dealextreme).

My initial LED order was from Kaidomain. The 3 in one combination lens is from Dealextreme.

 

Quality from these sites vary. Some people love them, others hate them...

Cree LEDs are "binned" according to brightness, Q5 is of the brightest. However the bin is not indicated on the LED, so you just have to take their word...

 

A more reputable supplier is Cutter (Australia). You pay a bit more.

 

My last order was from Cutter.

 

There does not seem to be much difference between LEDs from Cutter and Kaidomain.

 

You have to be careful handling the LEDs, irrespective from where you purchase.

The primary lens glued onto the LEDs is easily dislodged, especially when fitting the single lenses which clip on. These are meant to be clipped on (and glued) once. I have messed up a few LEDs removing the clip-on lenses. They still work, but light distribution is just not the same.

 

Buckpuck driver works fine with the Cree LEDs; you just need to make sure your input voltage is high enough for the output current to stay regulated (sum of forward voltage + ~1V for the driver).

 

 

mountain_lion2008-09-23 15:30:28

[Hog_]

 

 

 

 

 

I only saw this one now. AWESOME!!!! That looks great! What kind of endcaps are those? Where can I get them? Plumbing section? I haven't seen anything like that.

 

Man that looks cool!

 

EDIT: Nevermind, I see you already answered that. Note to self: Do not hub while drunk.

 

I go sleep now.

 

 

 

Hog_2008-09-23 15:06:25

[mountain_lion]

 

 

This is just to give an idea of what you need as well as cost.

I had many items available in my collection of "stuff that might be useful for something sometime..."

 

Parts summary for 3 individual Cree LED light (costs approximate):

 

3 of Cree XR-E Q5 bin LED total R170 (DealExtreme / Kaidomain / Cutter)

3 of Lens and holder 8? total R50  (DealExtreme / Kaidomain / Cutter)

3 of Brass Conex stop-ends (end caps) total R60 (hardware store)

T-bracket @ R10 

Screws R20

Driver (e.g. Buckpuck or bflex) R250 (Rabtron / Cutter / TaskLED)

Wires, solder, heat sink paste, silicone etc. R20

Switches, plugs (design / driver dependent) R50??

L-bracket to fit in LED flasher mount @ R10

LED flasher mount R? (I had one)

Battery pack (12V to 14V) + Charger e.g. Li-ion ~R500

 

Total parts: ~R1200

Note that the battery and charger makes up approximately half of the total cost. NiMH AAs will work as well, but you need at least 10; 12 are better.

 

Labour: you decide...

 

Remember to include shipping, duty and VAT if you order online from international suppliers.

 

Mounting the light on the bike is the most difficult part of any DIY light project.

You need to play with it and see what works for you.

I ended up hanging this light from the LED flasher mount, because of its weight. Was not stable other way round (as pictured here). Unfortunately this drops the light to behind the gear and brake cables.

 

Edit: 2009

Latest mounting method is L-bracket padded with hi-density foam and strapped directly to the stem with rubber band (cut from old car tube).

Very stable and can be slightly adjusted while riding.

Will take and post pic later...

 

 

mountain_lion2009-04-03 14:37:44

[mountain_lion]

Parts list for the triple Cree on round heat sink:

 

 

Similar parts list to above, but the mounting hardware is replaced by a heat sink and Al disk machined on the lathe.

Short section of 50mm PVC pipe and a 50mm PVC coupling (modified on lathe) is used to enclose the LEDs and hold the lens in place.

 

This is not a common heat sink (from old PC); I only had one.

 

Lenses replaced by combination lens from DealExtreme R30.

 

No major difference in cost.

 

A much lighter light (Al is lighter than brass), but more difficult to construct.

 

 

[BigGuy]

Battery pack (12V to 14V) + Charger e.g. Li-ion ~R500

 

Where did you get the battery pack and charger?

[mountain_lion]

 

 

 

Battery pack (12V to 14V) + Charger e.g. Li-ion ~R500

 

 

Where did you get the battery pack and charger?

 

www.all-battery.com

 

There are better batteries available but shipping to SA usually makes it way too expensive to consider.

I ordered from All-Battery with USPostal shipping i.e. SA Post office on this side. All arrived safely; I think within 2 weeks from order.

Paid via PayPal.

There might be local suppliers of Li-ion batteries in SA too, but I could not find any online. Maybe try the yellow pages...

mountain_lion2008-09-28 14:21:36

[BigGuy]

Thanks Mr Lion.