Kilo-Lumen bike headlight

Step 6 Machining the Slide Mount

The slide mount that I use is from PlanetBike. They sell it as a replacement for a few dollers. The great thing about their site is that they encourage the fixing of old or broken headlights rather than replacement. Thus they offer complete replacement parts for their products. If only more copmanies would take that approach!

Anyway, lest you think I am getting paid... I had bought a really crappy Planet Bike headlight a few years ago and decided to use the same old mount which is actually very well made.

I just needed a matching base for my headlight. I took measurements from the headlight that I had and replicated it in aluminum.

Here's where I will update this with a diagrammed drawing at some point, but to summarize, the slide is about 100 mils thick, and just under 0.75 inches wide. Make sure to machine a small gap for the locking hook.

I made this slide from two pieces. 1 piece is that 1/4 inch aluminum plate called out in the BOM. The other is the 62.5 mil sheet called out. Screws hold the two together as seen in the picture. Again, the milling machine came in handy here, this time with smaller end mills (1/8 inch I believe).

Comments

[mortso]

Why didn't you use a "T" cutter end mill to cut your mounting slot?

[kc6qhp]

Didn' have one :)