I lost my bike light a while ago, and now with shorter days aproaching i will have to ride my bike to school in the dark and at night more often. So thats where the homemade one comes in. I wanted to make a bright, yet clean looking, and compact light. The total cost is VERY low (may be higher if you dont have the battery and charger...but i already had them laying around) below you can see the before and after from the stock light to the finished one(both pics are taken from the same spot and in complete darkness):
Step 1: Materials:
-small generic flash light
-krypton "kpr112" bulb from radio shack
-some wire that has the positive and negative connected together(if that makes sense) like an old light plug, or speaker wire.
-7.2v battery and charger + male connector
-some miscillanious screws
-a handle bar mounted reflector
-a heat gun or stove
Step 2: Battery Holder
Lets start with making the battery holder (gives your hot glue gun and soldering iron time to warm up) (another note: if you have soldering iron, i suggest investing in a soldering gun) To get the level of brightness and endurance i wanted, simple "aa" or "aaa" batteries would not work efficiently, or allow the light to be very small. I decided to use a 7.2v rc car battery i had. It is rated at 3300mah so it will last for many hours before a charge is necessary. to keep the actual light small, and the overall look "clean" i disguised the battery as a sport bottle. I simply removed the inner core of the cap with wire cutters so the wiring could come through the top. The rest of this will be included in the wiring section.
Step 3: Cut the Light
To cut the light to shorten it i used a hacksaw, it was quick and painless:
Step 4: Start Wiring!
Now lets start with the wiring...the fun part! remove the bulb holder from the head of the light(should twist, unlock, and pull out) then use something with a fine point to pop the square metal plate in the center up as shown. Then wrap the stripped positive wire around the square and back on its self. then it should be ready to be soldered in place. i added a few dabs of hot glue after this to keep from pulling out.
Step 5: Wiring the Ground
Step 6: Making the Handlebar Mount
Step 7: Finishing Up
here is what it looks like on the bike: (you can figure out a system to clean up the look of the wire...this was just for the pic)
here is a pic of what it looks like with the push button switch aswell(recommended...you should be able to figure it out, add a comment if you have a question)