High power LED bike head light with integrated heat sink

Step 3 Cut front lens space

We also need to cut the front cap shorter to match the lens height. Using the lens as a guide, cut the front 3/4" cap to size as shown. File the cut flat and square and test fit the lens. The lens should sit flat on the inside face of the cap and have some amount of the copper cap sitting proud of it as a lip to protect the lens from impact and scratches. See pics.