Instructables

Super bright, cheap, and small bike light!

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Picture of Super bright, cheap, and small bike light!
stock light shine 4.jpg
Disclaimer: I am not responsible for your actions. if you cut, burn, electricute or hurt yourself in anyway i am not responsible. always be safe and use the appropriate protection. safety goggles are recommended.

 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):
 
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Step 1: Materials:

Picture of Materials:
bulb needed 5.jpg
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.
-sport bottle
-7.2v battery and charger + male connector
-solder equipment
-hot glue
-electrical tape
-some miscillanious screws
-a handle bar mounted reflector
-a heat gun or stove

Step 2: Battery holder

Picture of Battery holder
bottle cap 1.jpg
bottle cap 2.jpg

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.

Cool. Most of those generic flashlights have terrible reflectors, but a few aren't too bad, and they take Maglite bulbs. You can even use a NiteIze $5 LED and it will probably run literally for days with that battery. Thanks. I was thinking of doing this with a cheap flashlight and drill batteries, for one of my road bikes.