I've decided some time ago to build my own bike lamp based on SSC P7 LED. Sounds nice but instead using lathe and aluminium etc, I cut some corners and that instructable shows how quickly I've made fully functional bike light.
At first of all I've purchased drop-in SSC P7 (led+mirror+driver) plus glass (both items costs approx 16 quid from dealextreme) also some bits and pieces came from maplin: switch, battery holder connectors (all together about fiveish).
Now a bit of explanantion why I called it "Tomato Bike Lamp". Enclosure is made of tomato ketchup lid and tomato puree tin. As I said poor man design ;-)
Rest of the small bits and pieces like grommets, old lamp mount, screws and washers, cable, velcro strap and nylon fabric I found at home or work.
Also I've used primer and black paint (some spirit/degreaser and sand paper), soldering iron, file, snippers, utility knife, drill and bits.
Step 1: Body
Step 2: Body
Removed roughly stuff from inside of the cap by snipers, and than using utility knife/sandpaper made it perfectly fit to tin size, also glass and led itself fit very tight inside.
Step 3: Painting
Step 4: Asembling - Handlebar Mount
At first of all handlebar mount. Inside I've made big washer for better support.
Switch and cable grommet
Under the red ring I've added some silicone glue to keep it water tight.
Step 5: Battery Pack
At the moment I keep the batteries in plastic bag wrapped by rubber bands ;-) (I know it looks ugly but is only temporary solution). Fortunately I have Topeak frame bag so I can keep the "battery pack" inside for time being.
I've found old bag (fabric donnor) and I'll sew sort of bag/pouch with Velcro strap to attach it to stem or handlebar.
If you ride in low temperatures, consider bigger pouch or box and add some insulation (which I'll do probably).
Step 6: Finished
Step 7: Final Test and Thoughts
Probably for proper road/MTB you'll be fancy to have something which looks more neatly, but for now that's enough. In the future I'm planning replace driver, because I heard that standard dealextreme driver is crap and replacing the driver will give me more light output.