Instructables

Easy 800-3000 lumen LED bike light (or video light)

Picture of Easy 800-3000 lumen LED bike light (or video light)
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The project goal is to make a powerful LED light which can be used as a bike (ATV, snowmobile) or a video light.

This project is very customizable. You can use various LEDs and optics combinations. This project goal is to make a "3000 lumen" light.

The required parts:
1) Housing. The housing used in this project can fit almost anything up to 35mm in diameter. (http://www.easy2led.com/index.php?main_page=product_info&cPath=65&products_id=194)

The housing has a pill which can be screwed at almost any depth inside the shell.

2) LEDs. Triple XML board and matching optics. In this project - Ledil CUTE-3 and some Chinese noname optics.
3) LED driver. The choice depends on the available LEDs and power source. In this case it is a 2.8A buck driver (http://daoriginal.da.funpic.de//data/Buck Converter/Buck Converter.pdf)
4) Switches and wires, thermal paste.
 
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Step 1: Preparing the pill

Picture of Preparing the pill
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The pill has 2 holes already drilled. In this case I had to drill 2 additional holes: one for the wires and another for the screw.

Applied some thermal grease and installed the LED board.

Step 2: Driver installation

Picture of Driver installation
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Pull the wires through the hole, solder them to the LED board. Don't forget to check for shorts after this step!

Step 3: Pill installation

Picture of Pill installation
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Put some thermal paste on the pill threads and screw it at desired depth. Drop the optics on the LEDs and put the front glass with the o-ring. Screw down the tiny screws, but be careful with the torque - the plastic front ring can crack if you over-tighten.

Step 4: Rear cover assembly

Picture of Rear cover assembly
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Drill the necessary holes for the wires, pull the wires through the holes and solder them to the driver board wires. Insulate the solder joints.

Not pictured here: use zip-ties as strain relief, another possibility is to use a cable gland.