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All-in-one LED bike light

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mattthemuppet2

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#1
last winter I felt the need for a non-flashing bar light on my commuter. I have a non-flashing light on my helmet (very helpful for the "please don't pull out and kill me" moments) and a flashing light on my bars, but the strobe effect on my bars is a bit distracting in the dark and a non-flashing bar light would get me more forward visibility and let me keep the attention catching flashing light.

The mechanic at my local bike store also gave me the guts of a Lezyne all-in-one front light (battery is part of the light), so I'll be using the control/charging board from that, which simplifies things a bunch.

anyway, design will be 2 LEDs in parallel (Cree XP-G2 and XP-L) with 10deg optics, the Lezyne Macrodrive board, 2 Panasonic NCR18650B batteries (~3400mAh each) in parallel, momentary switch at the back. This will also be my very first "from solid" bike light, now that I have a mill. One cavity on the front for the LEDs with a nice thick piece of lexan, which should also give some side lighting. One cavity underneath for the batteries and driver.

Squared up a nice piece of alu to the right size last night with my facemill (about to start the larger side)


and bevelled the edges with a 90deg router bit


next up is drilling the holes for the charging port and switch, then starting on the LED cavity
 

mattthemuppet2

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#2
finished the back end - hole for a charging cable and switch, plus some grooves for water breaks and cooling


cut off the excess material at the front of the light using the bandsaw


cut the overhang to size and the recess for the lexan front plate


now need to grind a face grooving cutter for the o-ring grooves and bore the recesses for the LEDs
 

mattthemuppet2

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#3
did the layout for the LED recesses and o-ring groove


and ground a broken 2mm endmill :)() into a face grooving tool


however I ran out of both clearance between the tool and the overhang and energy, so I'll grind the tool down to fit, hopefully tonight.
 

mattthemuppet2

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#4
ground down the shank of my face grooving tool last night and cut the o-ring grooves.


Then drilled and started to bore one of the LED recesses. first time boring on the mill, boy it takes forever compared to the lathe! Should be able to finish off the LED recesses this weekend, after I've cut the grass, built some shelves for the shed and given my bike a service (new chainring, chain, clean cassette etc).
 
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