Bullnose LED Bike Light and Dynamo USB Charger

Step 4: Handlebar Work

Wiring the handlebars was pretty straight forward. The dynamo is grounded through the AC frame.  All the DC parts therefore have to be protected from the bare metal.

11/30/2010 - yea that dinky switch worked for about ~2 months of oregon rain... (piece of !>#()
any ideas for a good waterproof switch?

I got the little PCB kit from Radio Shack for ~$2.  It's similar to the one listed below.  I had to cut the board down to size to fit it into the handlebars. I used hot glue to protect the PCB and diodes. (thank Jay for the idea). http://www.radioshack.com/product/index.jsp?productId=3173937

The qty(4) diodes 1N5818 can be found here for $0.38 each:
http://search.digikey.com/scripts/DkSearch/dksus.dll?Detail&name=1N5818FSCT-ND


All the parts 'n pieces get inserted into the handlebars. Wrapped some of the wires under the handlebar tape (see pic).

Filled up the holes with a glue gun for weather protection.