Prototype version
Photos
(click to enlarge)
LED configuration
Regulation Method
Lens System
Batteries and Charger
Housing Method
Advantages
Disadvantages
Prototype 1 - Resistor limited 10 watt module using Mag-lite reflector. Weight 6.2 oz.
DX SKU-5876 10 watt module mounted to heat sink with JB Weld.
Two, 2 ohm 5 watt resistors in parallel to limit current. No on/off switch.
Modified reflector from Mag-lite. Attached with GE Silicone II sealant. Translucent notebook cover used to diffuse beam. Beam is very broad.
12 volt lead acid gel cell type battery with a Yuasa "Smart Shot 900", model 12V900 battery charger. Battery connector surplus molex type.
Surplus heat sink from a TO-3 power transistor. Handlebar clamp from Rockland Tool Co. plastic clamp 4” size.
Only a test light to see how well the resistor worked and if calculated current was achieved. Might be good for a camp light if a fan was mounted for cooling.
Beam so wide to be almost useless for bike riding. Maybe in the woods. Gets very hot. Was only built for an experiment.
Prototype 2 - Triple Cree, Buckpuck regulator with variable brightness, surplus power supply heat sink. Weight 8.3 oz.
Three Cree XR-E 7090 3 watt LEDs in series. bonded to head sink with JB Weld epoxy.
Luxdrive 3021 Buckpuck regulator, 1000 ma output, with external 5K pot to control brightness.
L2
Optics OPTX Series lens for XLamp 7090 series LED with
Optional
8 deg diffuser
Attached with GE
Silicone II sealant.
12 volt lead acid gel cell type battery with a Yuasa "Smart Shot 900", model 12V900 battery charger. Battery connector surplus molex type.
Surplus heat sink from linear power supply cut to size. Handlebar clamp from Rockland Tool Co. plastic clamp 4” size
Compact heat sink design compared to Prototype 6. Has excellent beam for road. Diffusers can be removed to concentrate beam. Nice control with the potentiometer. Cost about $45 to build.
Pot while the recommended 5K ohms, maxes out brightness at only 40% open. The bare beam is not evenly distributed with the L2 optics. Diffusers are need to smooth out beam pattern, which is ideal for road riding.
Prototype 3 - Double Cree with individual current regulators and switches. Weight 6.5 oz.
Two Cree XR-E 7090 3 watt LEDs in series bonded to head sink with JB Weld epoxy.
DX SKU-4255 circuit board for 3 watt Cree and SSC emitters. Individual clicky on/off switchs.
L2
Optics OPTX Series lens for XLamp 7090 series LED with
Optional
8 deg diffuser
Attached with GE
Silicone II sealant.
6 volt lantern battery or 4 NiMH AA batteries with a Maha MH-C401FS charger. Battery connector is surplus computer 5/12v connector.
1 ½ “ aluminum angle stock. Electronic perf board and standoffs. Angle stock bonded with JB Weld. Handlebar clamp from Rockland Tool Co. plastic clamp 4” size
Simple to operate with clicky switches between one and two LEDs. Able to increase battery duration when using the 4 AA cells. Diffusers can be removed to concentrate beam. Cost about $20 to build.
The mounting method of the two LED drivers is complicated and messy for this prototype. New unit should be simplified like experiments 5 and 6. The bare beam is not evenly distributed with the L2 optics. Diffusers are need to smooth out beam pattern
Prototype 4 - Single Cree Q5 with heat sink, On/off clicky switch. Weight 3.5 oz.
Single Cree XR-E 7090 3 watt LED bonded to heat sink with Arctic Silver Thermal Adhesive
DX SKU-1885 circuit board for 3 watt LEDs. Single clicky on/off switch.
L2
Optics OPTX Series lens for XLamp 7090 series LED with
Optional
8 deg diffuser
Attached with GE
Silicone II sealant.
6 volt lantern battery or 4 NiMH AA batteries with a Maha MH-C401FS charger. Battery connector is surplus computer 5/12v connector
1 ½ “ aluminum angle stock. Surplus TO-3 transistor heat sink. Parts bonded with JB Weld. Handlebar clamp made from a Rockland Tool Co. plastic clamp 2” size
Great light with the Q5 Cree LED. Cost about $15 to build.
The heat sink makes this a one of a kind. See next version for better production model. The output is 18% greater for the Q5 than the P4 but costs twice as much as the P4 LED. The bare beam is not evenly distributed with the L2 optics. Diffusers are need to smooth out beam pattern
Prototype 5 - Single Cree P4 with aluminum stock heat sink. Weight 3.5 oz.
Single Cree XR-E 7090 3 watt LED bonded to heat sink with Arctic Silver Thermal Adhesive
DX SKU-1885 circuit board for 3 watt LEDs. Single clicky on/off switch.
L2
Optics OPTX Series lens for XLamp 7090 series LED with
Optional
8 deg diffuser
Attached with GE
Silicone II sealant.
6 volt lantern battery or 4 NiMH AA batteries with a Maha MH-C401FS charger. Battery connector is surplus computer 5/12v connector
1 ½ “ and 3/4” aluminum angle stock. Angle stock bonded with JB Weld. Handlebar clamp made from a Rockland Tool Co. plastic clamp 2” size
Simple construction and compact design makes it easy and light to carry along with NiMH AA batteries for occasional night riding. Cost about $15 to build.
Only have one brightness so can not stretch duration of batteries beyond 1 ½ hrs. The bare beam is not evenly distributed with the L2 optics. Diffusers are need to smooth out beam pattern
Prototype 6 - Triple Cree, variable brightness, aluminum stock heat sink. Weight 7.7 oz.
Three Cree XR-E 7090 3 watt LEDs in series bonded to heat sink with Arctic Silver Thermal Adhesive
Luxdrive 3023 Buckpuck regulator,1000 ma output, with external 5 K ohm pot to control brightness.
L2
Optics OPTX Series lens for XLamp 7090 series LED with
Optional
8 deg diffuser
Attached with GE
Silicone II sealant.
12 volt lead acid gel cell type battery with a Yuasa "Smart Shot 900", model 12V900 battery charger. Battery connector is surplus computer 5/12v connector
1 ½ “ and 3/4” aluminum angle stock. Angle stock bonded with JB Weld. Handlebar clamp from Rockland Tool Co. plastic clamp 4” size
Easier design for anyone to make than the prototype in Prototype 2. Otherwise it is the same. Has excellent beam for road. Diffusers can be removed to concentrate beam. Nice control with the potentiometer. Cost about $45 to build.
Pot while is recommended 5K ohm, maxes out brightness at only 40% open. The bare beam is not evenly distributed with the L2 optics. Diffusers are need to smooth out beam pattern which is ideal for road riding.
Prototype 7 - Triple SSC, Mag-lite “C” head, bFlex controller. Weight 8 oz.
Three SSC Z-power LEDs in series bonded to heat sink with Arctic Silver Thermal Adhesive
DX SKU-4630 49.7mm tri-optic Reflector. The beam is a sharply defined round, evenly distributed cone pattern of about 30 deg.
12 volt lead acid gel cell type battery with a Yuasa "Smart Shot 900", model 12V900 battery charger. Battery connector is surplus computer 5/12v connector
Mag-lite “C” head unit and Fuji film cassette. Handlebar clamp from Rockland Tool Co. plastic clamp 4” size
The bFlex controller is nice with 5 precise levels of brightness. Automatic temperature monitoring good. Beam has good cutoff to prevent glare to oncoming traffic. Cost about $55 to build, if you have to buy the Mag-lite.
The beam is a little too wide at 30 deg for fast road riding but good for trails. Unit gets hot and this Mag-lite “C” design does not have sufficient heat dissipation.
Prototype 8 - Triple Cree, Mag-lite “D” head, Buckpuck regulator with variable brightness. Weight 9.5 oz.
Three Cree XR-E 7090 3 watt LEDs in series bonded to heat sink with Arctic Silver Thermal Adhesive
Luxdrive 3023 Buckpuck regulator, 1000 ma output, with external 5 K ohm pot to control brightness
DX SKU-1911 48.16mm tri-optic Reflector. The beam has an evenly distributed fall off out for a 30 deg cone. Alternate tri-optic lenses has 5 deg or 14 deg beams
12 volt lead acid gel cell type battery with a Yuasa "Smart Shot 900", model 12V900 battery charger. Battery connector is surplus computer 5/12v connector
Mag-lite “D” head unit, and hacksawed stub of battery tube. Handlebar clamp from Rockland Tool Co. plastic clamp 4” size
The brightness pot is simple to use vs the bFlex controller. The “D” head has more mass and better ventilation at the rear to eliminate heat. The tri-optic lens is interchangeable with other DX lenses. Cost about $46 to build, if you have to buy the Mag-lite.
Feels quite heavy compared to the lights using the aluminum angle stock. Can swap out optics with two other tri-optics that fit.
Prototype 9 – Module with three 3 watt LED emitters on plate, Mag-lite “C”. Buckpuck regulator with variable brightness. Weight 8.5 oz.
Three Cree (?) 3 watt emitters on a prefab plate. DX SKU-5225
Luxdrive 3023 Buckpuck regulator, 1000 ma output, with external 5 K ohm pot to control brightness
DX SKU-1912 48.16mm tri-optic Reflector. The beam has an central 14% spot with some spill. Alternate tri-optic lenses are available.
12 volt lead acid gel cell type battery with a Yuasa "Smart Shot 900", model 12V900 battery charger. Battery connector is surplus computer 5/12v connector
Mag-lite “C” head unit, and hacksawed stub of battery tube. Handlebar clamp from Rockland Tool Co. plastic clamp 4” size
Much easier to build with the prefabricated LED module. The tri-optic lens is interchangeable with other DX lenses. Cost about $44 to build, if you have to buy the Mag-lite.
A little tight to install the Buckpuck and pot. Beam has a slight blue on the fringe with a bright core. Not able to swap optic easily.
Prototype 10 – Red Cree 3 watt LED, 17 multi-mode controller, 1 AA battery. Large heat sink.
Single Cree red LED DX SKU-1776 bonded to Al angle stock with Arctic Silver Thermal Adhesive
KAI SKU-3151 multi-mode regulator with 17 modes in 3 groups. Regulator will hold last setting when turned off.
L2 Optics OPTX Series lens for XLamp 7090 series LED. Oval sub-lens with 8x25 deg pattern.
Single AA battery in Radio Shack battery holder.
1 ½ “ aluminum angle stock as heat sink and mounting plate. Surplus reflector holder used to attach to seat post.
The 3 watt red LED in conjunction with the L2 optics and sub-lens gives the most powerful rear flasher I have ever seen for a bike. Lasts 6 hr for an evenings biking with NiMH batteries. The “Police strobe” flasher is very effective.
Has two switches , on/off for power and make/break to setup the modes and groups. The setting of the modes and groups is very confusing at first, must practice changing modes. Unit is susceptible to damage with external parts.
Prototype 11 – White 3 watt Cree, multi-mode controller, 2 AA battery. Small internal heat sink. Weatherproof case.
Single Cree white LED DX SKU-3417 screwed to small internal Al heat sink.
DX SKU-10084 multi-mode regulator with 5 modes. Single clicky on/off switch.
VistaLite case has minor lensing effect in clear section of cover.
Two AA batteries in original VistaLite battery holders.
Original VistaLite case used.
Unit is self contained and weatherproof. Very bright amber flasher, more than original VistaLite Xenon strobe. The 5 mode setup is very simple.
Can not be used in the high steady mode because of small heat sink. NiMH batteres only last 4 hours. The Vistalite case is no longer available.
Prototype 12 – Red Cree # watt LED, 17 multimode controller, 1 AA battery. Small internal heat sink. Weatherproof case.
Single Cree red LED DX SKU-1776 bonded to small internal Al heat sink with Arctic Silver Thermal Adhesive
DX SKU-7882 multi-mode regulator with 17 modes in 3 groups. Regulator will hold last setting when turned off. Single clicky on/off switch.
VistaLite case has minor lensing effect in clear section of cover.
Single AA battery in original VistaLite battery holder.
Original VistaLite case used.
Unit is self contained and weatherproof. Very bright light with a smooth broad beam. Lasts 6 hr for an evenings biking with NiMH batteries. The “Police strobe” flasher is very effective.
Can not be used in the high steady mode because of small heat sink. The setting of the modes and groups is very confusing at first, must practice changing modes. The Vistalite case is no longer available.
Prototype 13 – Red multi-mode flasher with two LEDs, 1 AA battery. Weatherproof case.
Two 1 watt red LEDs DX SKU-11017 bonded to Al heat sink with Arctic Silver Thermal Adhesive
DX SKU-7302 multi-mode regulator with 17 modes in 3 groups. Regulator will hold last setting when turned off. Single clicky on/off switch.
VistaLite case has minor lensing effect in clear section of cover.
Single AA battery in original VistaLite battery holder.
Original VistaLite case used.
Unit is self contained and weatherproof. Beam wide and tall. Lasts for over 24 hrs with 1 AA battery. The “Police strobe” flasher is very effective.
Unit is weaker than Prototype 12 or 10. Beam pattern not as good for keeping glare down. The setting of the modes and groups is very confusing at first, must practice changing modes. The Vistalite case is no longer available.
Prototype 14 – As Prototype 6 but with 8 degree optics.
Three Cree XR-E 7090 3 watt LEDs in series bonded to heat sink with Arctic Silver Thermal Adhesive
Luxdrive 3023 Buckpuck regulator,1000 ma output, with external 5 K ohm pot to control brightness.
DX SKU-1920 optics with 8 degree beam, specifically for Cree XR-E7090 LEDs.
12 volt lead acid gel cell type battery with a Yuasa "Smart Shot 900", model 12V900 battery charger. Battery connector is surplus computer 5/12v connector
1 ½ “ and 3/4” aluminum angle stock. Angle stock bonded with JB Weld. Handlebar clamp from Rockland Tool Co. plastic clamp 4” size
Much easier to attach the optics because of snap on optics. The beam is good for long straight roads and keeps glare away from on coming cars. Nice control with the potentiometer. Cost about $45 to build.
Pot while is recommended 5K ohm, maxes out brightness at only 40% open. The beam is very narrow and would not be good on a winding road or trail.
Prototype 15 - Red multi-mode flasher with two Cree LEDs, 1 AA battery. Weatherproof case.
Two Cree red LEDs DX SKU-1776 in series bonded to heat sink with Arctic Silver Thermal Adhesive.
DX SKU-7302 multi-mode regulator with 17 modes in 3 groups. Regulator will hold last setting when turned off. Single clicky on/off switch.
VistaLite case has minor lensing effect in clear section of cover.
Single AA battery in original VistaLite battery holder.
Original VistaLite case used.
Similar to Prototype 13 except that the brightness is increased and the beam is tighter. Lasts for over 24 hrs with 1 AA battery. The “Police strobe” flasher is very effective.
Will be to bright to ride behind in a group if in the beam. The Vistalite case is no longer available.
Prototype 16 – Red multi-mode flasher with two LEDs, 1 AA battery. Commerical clear case. Splash resistant case, open battery.
Two 1 watt red LEDs DX SKU-11017 bonded to Al heat sink with Arctic Silver Thermal Adhesive
DX SKU-7302 multi-mode regulator with 17 modes in 3 groups. Regulator will hold last setting when turned off. Single clicky on/off switch.
None. Clear faceplate.
Single AA battery in Radio Shack battery holder.
Dealextreme rear flasher DX SKU-1211 case gutted internally.
Internals as Prototype 13 but built from case that is available now. Easy to change battery. Very wide pattern with no lens. Lasts for over 24 hrs with 1 AA battery.
With the broad pattern, riding behind this bike might be hard on the eyes.
Prototype 17 – Adaptation of Walmart trailer red clearance light.
Walmart trailer clearance light, 2 red LEDs Piranha brand, V168R
None, LEDs are limited by internal resisters.
Small internal lens.
Uses 12 volt gel cell in parallel with the main front light.
None, used as purchased. $7
No construction required and is excellent for rear bike light in steady mode.
Requires a 12 volt source.