Beam shots show a building at night 100-ft away illuminated by this LED bike light.
Detailed Specs and Parts List are given at the end of Step 8.
Step 1: Building the Enclosure
A. These are the parts needed for the enclosure and shown before cutting to size: Lexan MR10 plastic, 1/16-inch x 3/4-inch aluminum L-bracket, Hammond enclosure, heat sink.
B. Cut parts to size: 3/4-inch section from enclosure, aluminum back bezel, Lexan front bezel, heat sink slices.
Step 2: Attach the LEDs
A. Trim LED stars to fit inside enclosure.
B. Position stars on back bezel with an extra piece of L-bracket which is same thickness as Hammond enclosure.
C. Rotate center star 180-degrees so the + and - tabs are next to each other on adjoining stars.
D. Glue stars with Arctic Silver thermal adhesive, then clamp until cured (five minutes).
E. Good thermal management is essential for LEDs. Glue heat sink slices to top and back of L-bracket using Arctic Silver thermal adhesive.
Step 3: Wiring the LEDs
A. Wire stars together (two small red wires) between + and - tabs.
B. Drill another hole in back bezel for incoming power. Add shrink tubing for strain relief on each side of bezel.
C. Drill holes in base of lens holders to route black negative power wire.
D. Glue lens bases to stars, preferably with Loctite 460 superglue.
E. Solder incoming power wires to stars (white + and black -).