A front bike light for your helmet, it goes where you go and shines where you look! No more multiple handlebar mounts on different bikes, broken handlebar mounts, cumbersome external batteries, etc.
After breaking several cheap plastic mounts I'd had enough of bike mounted lights. Enough I say! Why can't mfg's make fiber reinforced mounts!
Having used headlamps extensively for camping and hiking I decided it was time for a helmet mounted light that I could point where I wanted, especially in driver's eyes to alert them of my presence.
Step 1: Acquire LED Flashlight
Step 2: Materials List
2) Some sort of thick plastic bendable packaging material (~1mm thickness)
3) Snip pliers or wire cutters (for cutting zip ties)
4) Lighter (bic preferred)
5) Sharpie (never leave home without it!)
6) Four zip ties (may need more or less depending on size)
7) Four rubber o-rings sized for the flashlight barrel (again, may need more or less)
8) Led flashlight
9 ) Scissors (not pictured)
Step 3: Protecting Styrofoam Ribs in the Helmet
However, zip ties putting pressure on the Styrofoam underside of the helmet when tightened was a problem. It caused deformation of the Styrofoam even without being fully tightened.
See photo for detail.
Step 4: Distributing the Load
Find some sort of plastic packaging that is fairly sturdy, here I show the use of a cookie container. Using the sharpie mark an oval appropriately sized to the area of the styrofoam you wish to protect. Then using some scissors, cut the oval out (see 2nd photo).
The third photo shows the load distributor in place. You will see how this works with the zip ties in a later step.
Step 5: Securely Mounting Metal to Plastic?
Two fore and aft ensured a nice interface between the light and the plastic helmet skin. See photo for before/after.
Step 6: Begin Assembly
1) I found it allowed me the best alignment of the light so the spot was shining where my eyes looked when they were straight ahead and relaxed.
2) I may add another light to the other side that has a strobe/blink feature for even greater visibility.
Please note in photo 3 the zip ties are not fully snugged up. I left them a little loose so that I could reposition the light and get the alignment of the beam spot just right before cinching up the zip ties.
To get the proper alignment, put the helmet on as you normally would, turn the light on, and then use a dark wall that is at least 15' away from you. Adjust the light so that it shines where your eyes normally look when relaxed and looking straight ahead.
Photo 4 shows the piece of plastic we're using to distribute the load across the styrofoam rail.
Step 7: Finalize Assembly
I found that the zip ties, when encountering sharp bends eventually set into their final position and loosen up a bit. leaving the 1/2 inch of zip tie allows you to use a pair of pliers to grip onto them and tighten up if they loosen.
For safety's sake, use a lighter to melt the ends of the zip ties so they're not sharp and you don't cut yourself on them. Believe it or not industries that work with zip ties a lot actually have "Zip Tie Safety" classes. A sharp zip tie at eye level can do some serious damage.
Step 8: Wrapup and Future Ideas
I am considering switching to smaller/lighter LED flashlights that use a single rechargeable 18650 cell battery and also mounting two lights to the helmet. One to run for illumination and the other to run in strobe mode, both pointed forward.
Hope you enjoyed and be safe out there!