DIY Cree LED bike light

[TreeDodger]

Here is my 2 cree Q5 bin light. I built a 3 led version as well but

found that mounted on my helmet 2 is plenty. I'm using a 3023-D-E-1000

Wired BuckPuck from www.ledsupply.com

 

 

 

All glued together with pratley steel. The led stars are glued with

thermal compound to 32x32 aluminium square tube and the lenses are

enclosed by 32mm round tube.

 

 

 

Have a look here for Marwi light mounts. I bought some helmet and handlebar mounts and they work well:

 

 

 

http://edinabike.com/page.cfm?PageID=62&action=details&sku=LT7419

 

http://edinabike.com/page.cfm?PageID=62&action=details&sku=LT7540

 

 

 

Currently using a 4Ah nimh battery with a charger I built myself (based

on a MAX713 smart charger IC). This was actually the biggest hassle, I

will try the 18560's from deal extreme.

 

The light is not finished yet, need to seal the whole thing up... and get a bolt to attach the mount to the light!

 

 

 

 

[markStockton]

Very nice work TreeDodger, I believe this may be the inspiration I need to do my helmet mounted light. 

[mountain_lion]

 

Looks nice TreeDodger.

You will have to post beam shots of course.

Which lenses did you use?

 

I prefer a bar mounted light as my primary light but also built a 2 LED helmet light (older lower power Luxeons) which is nice on twisty single track to compliment the tripple Cree on the bar.

Is this your only light?

 

Thanks for the mount info. What do Edina charge for shipping? Shipping often kills a deal.

 

 

mountain_lion2009-04-09 05:23:01

[mountain_lion]

PS when posting URLs please use this format: http://link_location

With BBcodes enabled (default on the Hub) this will be posted as a clickable link.

 

[Super_mil]

Is there any reason why you guys choose to use DealExtreme.com over Dealspot.co.za? They seem to be affiliated and tend to carry the same/similar stock.

 

 

 

Dealspot had a 35% off all stock on-line the other day and it motivated me to start with my own light(s).

 

 

 

Will post pics when there is something to show.

[mountain_lion]

 

Is there any reason why you guys choose to use DealExtreme.com over Dealspot.co.za? They seem to be affiliated and tend to carry the same/similar stock.

 

 

 

Dealspot had a 35% off all stock on-line the other day and it motivated me to start with my own light(s).

 

 

 

DealExtreme is often faster and usually cheaper.

 

DealExtreme site is easier to browse too.

 

There is also http://extremeshop.co.za

 

 

 

Cree R2 star:

 

DealExtreme US$6.32 say ZAR63.20 + 14%VAT = R72.05

 

Dealspot: R128.34

 

 

 

I have paid handling and duty on some DealExtreme packages but not on all. Still 128.34 / 72.05 =  1.78 and duty is never 78%!

 

So that is how they manage to offer 35% discount...

 

 

[TreeDodger]

Will post links correctly next time!

 

I used L2 optics

Lenses (6 degree): L2-OPTX-1-006

1 x 8 degree diffuser: L2-OPTX-1-DIF8

1 x 16 degree diffuser:  L2-OPTX-1-016S

 

The lenses don't actually fit the cree LEDs, I had to machine bits away with a dremel to get it to fit and then glued them on.

 

This is my second light, first one is 3 led. I have only ridden with the 3 led and find myself riding at around 20% power most of the time so that I don't wash out the other guys lights!

 

I have tried both handlebar and helmet and I find a strong light on the helmet is all I need. I am doing the stargazer race in Montagu this weekend and will use the 2 led one evening and the 3 led the next. Will report next week but I am sure the 2 led will be plenty strong.

 

The 3 led is a bit heavy so I hope the 2 led will be more comfortable.

 

I bought the mounts from edina about 8 months ago and the shipping was $10 then so very reasonable.

 

 

[TreeDodger]

 

Will post beam shots next week...

 

I had to buy 6m aluminium tubing so if anyone wants pieces I'll sell it to you cheap cheap

 

I also have the small tube that the mount clamps onto.

TreeDodger2009-04-09 07:10:00

[mountain_lion]

 

 

 

I bought the mounts from edina about 8 months ago and the shipping was $10 then so very reasonable.

 

Things seem to have changed since. They now want a US$120 minimum order to ship internationally.

http://edinabike.com/page.cfm?pageID=109

You never know though; might be able to arrange something by emailing them first...

 

mountain_lion2009-04-09 09:04:35

[deanbean]

Great thread ML, inspired me to build my own. I was looking for an enclosure for the 18650 batteries and found this thread on MTBR forum.

http://forums.mtbr.com/showthread.php?t=457070

Can anyone tell me if it is possible to wire three LEDs to a on-off-on switch, so that you can have either two or three lights burning, depending on which side you switch it.

 

[mountain_lion]

 

Great thread ML' date=' inspired me to build my own. I was looking for an enclosure for the 18650 batteries and found this thread on MTBR forum.

http://forums.mtbr.com/showthread.php?t=457070

Can anyone tell me if it is possible to wire three LEDs to a on-off-on switch, so that you can have either two or three lights burning, depending on which side you switch it.

[/quote']

 

Thanks DB.

 

You can switch a LED in / out, but I do not recommend doing it.

With LEDs you usually use a constant current driver which can easily be used to dim all the LEDs.

Also note that not all constant current drivers are protected against open circuit load. Very important not to let the smoke out of the driver...

 

I have used an on-off-on three position switch with resistors in the control circuit of a Luxdrive Buckpuck to provide dim, bright and off settings.

 

 

[deanbean]

Thanks ML I've got a Luxdrive Buckpuck. Will use a potentiometer on it to dim the lights.

[mountain_lion]

A potentiometer will work and has the advantage of allowing continuous dimming between full and off. However most of the time 2 levels are

adequate for MTB use and much easier to select on the bike than turning a pot.

 

 

 

As said above, a three position switch with resistors chosen according

to the levels desired works well for me. Easy to select on the bike too.

 

 

My setup with the Buckpuck works like this:

• Off position is open circuit (infinite resistance), i.e. max current (or some resistance value if full brightness is not

  required) ,

• On to one side switches in the required resistor value for dim level and

• On to the other side is short circuit i.e. light off

 

[ENZO]

Respect Konafan,

 

Your solution is elegant and easy! Missioning with fancy li ion battries & chargers, imported LED's and LED drivers, heatsinks ETC, etc = was beaten. Li ion batteries tricky to work with, drivers complex to connect, heatsinks heavy, my experience with it.

 

The 3 x 2 w (cool white), 12volt cree downlight by sunfor in 50 mm irrigation pipe, with .8 Ah (+-2 hour use - weight +-500g ) or 1.5 Ah (+4 hour use - weight +-800 g), works awesome. Costs around R500 yes, (LED price R300, battery price R50 - R150, pipe R25, clamp R25). Plenty light, just might be too much for on coming riders...Only one mode setting and that is either on or off!

 

Old car charger - good job to chargE basic 12v lead acid batteries. These small batteries from Mantec Electronics.

 

Can't post pics, don't have permission on hub.

 

 

[Dun Man]

Hi !

 

Just got this mail from the guy who sells the stuff in CT,

 

His mail adress is :Gareth Scott [gareth@seamarine.co.za]

 

Good morning Douw ...I must apologize for the late reply ...I have just returned from a lengthy leave.

 

In the 12V range, I can offer...

 

...a 3 x 1W (3W total) unit ...retailing @ R325.00 incl VAT, or

...a 3 x 2W (6W total) unit ...retailing @ R375.00 incl VAT

 

Please note however, that we only recently picked up the Sunfor Dealership and have just moved premises as well. We have yet to place our first stock order with Sunfor, so delivery for the time being is 1 working week, ex JHB.

[ENZO]

thanks - ordered direct from Shannon at Sunfor in JHB, dhl'ed to CT. Sunfor head office have 3 x 2 w on back order, not sure if they have stock yet. Suggest you deal with JHB if you want downlighter faster. Important to go for Cool White.