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Helmet mounted bicycle light on the quick and cheap!

Step 6Begin assembly

Begin assembly
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See the photo montage below. As every bicycle helmet is different you will need to play around a bit with placement of the light and zip ties. I used an offset position for two reasons.

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.
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Author:goodgnus
Just another tinkerer.