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Step 6Installing the circuit into the handlebars...
Installing the circuit you just built into the handlebars is not complicated but you must be gentle to avoid damage to the delicate solder joints. The process I used is detailed below but I encourage you to modify the directions to best fit your specific application.
1) It is a good idea to test your lights and make sure they work one last time before you begin the installation. Troubleshooting after installation means pulling everything back out and can be a real headache.
2) With both bar plugs removed from the bike, carefully feed a scrap piece of wire in from the left until it comes out the right end of the handlebars. This will be used to pull the wires for the left LED back through the handlebars. The bike can be laid on its side allowing gravity to assist in feeding the wire through.
3) Attach the pulling wire you just ran through the handlebars to the wires of the left LED. You will be removing this connection later so do not go crazy with it; a small piece of tape will work fine.
4) Slowly and carefully begin pulling the wire you just attached to the left LED assembly back out the right end of the handlebars.
5) Before the left LED clears that end of the bar you will probably need to feed the battery assembly into the right end of the handlebars. I used a large screwdriver to gently push the batteries in as I pulled the wires through from the other end.
6) Once the left LED clears the end of the handlebars you can detach the pulling wire. Gently push the left LED into the hole you made in the left bar plug. Once the left LED is securely fit into the plug you can feed any excess wire gently back into the handlebar and reinstall the plug.
7) Test the lights like you did before. If there is a problem, go back and check all your connections.
One side down, one to go!
8) With the left half of the handlebars complete, it is time to install and position the reed switch. Rotate the piece of sponge so that the reed switch is facing up. Gently insert the reed switch assembly into the handlebar end and push it in far enough that the switch is centered under the right hand grip. I used a large screwdriver to get the switch positioned in just the right place. Take your time and get it exactly where you want it. If the switch is not at the top of the bars, or is to far off to either side of the grip it may not trigger reliably.
9) Test again. You do not want to get finished with the entire installation only to realize a wire came loose.
10) Once you are satisfied with the placement of the reed switch, install the right LED in the same way you installed the left LED. Be gentle as you feed any excess wire back into the handlebar because you do not want to disturb the placement of the reed switch assembly.
11) Now you need to test it again, but you already knew that.
Almost there!
12A) You will need to find the correct position to install the magnet on the glove. Do this by putting on the right handed glove and gripping the handlebars like you do while riding. Make a mental note of what area of the palm of the glove is closest to the reed switch you installed earlier inside the handlebars.
12B) If you wish to use this system without gloves, skip to Page 9 of this Instructable for glove-less trigger instructions.
13) Without removing the glove, slide the metal washer inside the glove's palm area. Try to get it close to where you think the magnet needs to go to be in position to trigger the reed switch.
14) Put the neodymium magnet on the outside palm of the glove and you will feel it stick to the washer on the inside of the glove. You can adjust the position by pulling the magnet away from the washer slightly and sliding it around until you find a position that is both comfortable and efficient for triggering the lights.
15) Neodymium magnets can oxidize so a quick spray with some sealant or a coat of nail polish will keep the magnet from getting rusty.
16) Once you are satisfied with the position of the magnet for maximum hand comfort and triggering ability you are done!
After you build it- If you have any tips, tricks, suggestions, or improvements for this instructable I would love to hear them. Please use the comments section or send me a private message and I will gladly add your tips and credit you for your ideas.
The next step contains FAQ's about the device.
1) It is a good idea to test your lights and make sure they work one last time before you begin the installation. Troubleshooting after installation means pulling everything back out and can be a real headache.
2) With both bar plugs removed from the bike, carefully feed a scrap piece of wire in from the left until it comes out the right end of the handlebars. This will be used to pull the wires for the left LED back through the handlebars. The bike can be laid on its side allowing gravity to assist in feeding the wire through.
3) Attach the pulling wire you just ran through the handlebars to the wires of the left LED. You will be removing this connection later so do not go crazy with it; a small piece of tape will work fine.
4) Slowly and carefully begin pulling the wire you just attached to the left LED assembly back out the right end of the handlebars.
5) Before the left LED clears that end of the bar you will probably need to feed the battery assembly into the right end of the handlebars. I used a large screwdriver to gently push the batteries in as I pulled the wires through from the other end.
6) Once the left LED clears the end of the handlebars you can detach the pulling wire. Gently push the left LED into the hole you made in the left bar plug. Once the left LED is securely fit into the plug you can feed any excess wire gently back into the handlebar and reinstall the plug.
7) Test the lights like you did before. If there is a problem, go back and check all your connections.
One side down, one to go!
8) With the left half of the handlebars complete, it is time to install and position the reed switch. Rotate the piece of sponge so that the reed switch is facing up. Gently insert the reed switch assembly into the handlebar end and push it in far enough that the switch is centered under the right hand grip. I used a large screwdriver to get the switch positioned in just the right place. Take your time and get it exactly where you want it. If the switch is not at the top of the bars, or is to far off to either side of the grip it may not trigger reliably.
9) Test again. You do not want to get finished with the entire installation only to realize a wire came loose.
10) Once you are satisfied with the placement of the reed switch, install the right LED in the same way you installed the left LED. Be gentle as you feed any excess wire back into the handlebar because you do not want to disturb the placement of the reed switch assembly.
11) Now you need to test it again, but you already knew that.
Almost there!
12A) You will need to find the correct position to install the magnet on the glove. Do this by putting on the right handed glove and gripping the handlebars like you do while riding. Make a mental note of what area of the palm of the glove is closest to the reed switch you installed earlier inside the handlebars.
12B) If you wish to use this system without gloves, skip to Page 9 of this Instructable for glove-less trigger instructions.
13) Without removing the glove, slide the metal washer inside the glove's palm area. Try to get it close to where you think the magnet needs to go to be in position to trigger the reed switch.
14) Put the neodymium magnet on the outside palm of the glove and you will feel it stick to the washer on the inside of the glove. You can adjust the position by pulling the magnet away from the washer slightly and sliding it around until you find a position that is both comfortable and efficient for triggering the lights.
15) Neodymium magnets can oxidize so a quick spray with some sealant or a coat of nail polish will keep the magnet from getting rusty.
16) Once you are satisfied with the position of the magnet for maximum hand comfort and triggering ability you are done!
After you build it- If you have any tips, tricks, suggestions, or improvements for this instructable I would love to hear them. Please use the comments section or send me a private message and I will gladly add your tips and credit you for your ideas.
The next step contains FAQ's about the device.
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