High power LED bike head light with integrated heat sink

Step 4 Form the electronics compartment

If you noticed, the Buck Puck is square and too big to fit in the 1" diameter section of the body. Never fear. The trick here is to form the back section so that the electronics just fit inside. I used a small chunk of aluminum held in a vice as a form (see pic) and pounded the rear section square with a hammer. Take your time and test fit the Buck Puck occasionally. Once you have the fit, go on to the next step.