Step-by-step instructions on how to build a rear mounted bike light with turn signals for day and night use, so drivers can see you and where you are going. All comments are accepted, I would like to hear ways i could improve this.
Step 1: Materials and Tools
-6 leds-color is a personal preference-Red/amber main light, yellow for turn signals
Don't use blue lights like i did, after making it i was informed blue is reserved for police
-2 mini-toggle switches
-1 Slide switch
-9v snap connecter
-1 Project box-any size bigger than 4"x 2"-aluminum cover is needed
-1 Bic pen or Mechanical Pencil
-Hot glue gun
Step 2: Optional: Prototype on Breadboard
Try Before building-use a breadboard. If you are not using a breadboard you may skip this step.
Step 3: Drill Holes for Aluminum Plate
Mark where the holes will need to be, on top of the box, having the plate facing away from the cover. Drill or ream holes so that the plate fits flush to the box. Screw the plate in-place with the thread of the screw is on the out side of the box.
Step 4: Mark and Drill Holes for Leds
Take the four leds and make them in any shape, i made mine in a square. mark and drill the holes. also cut holes where the wires will run for the turning lights. Cut the Bic pen barrel in half, theses will be mounted on the sides and used to hold the turning lights. Also cut a hole large enough for the slide switch.
Step 5: Solder Everything Together
Solder the components as shown in the schematic. Sorry for lack of pictures, i wasn't allowed to use the camera when i was soldering.
Before soldering the turning leds to the main components, solder on the main leads, and run the wires through the Bic pen you cut in half. Also before soldering the switches that will be mounted on the handle bars, drill a large hole in the top of the box.
Use only one negative wire for the 2 switches, to the handle bars, for the turn signals-at the end split it to two. Then from the 2 switches run two other wires bake to the leds. Also remember to cut the wires running to the handle bars longs enough that they will not limit your turning ability.
Step 6: Hot Glue Everything Into Place
Start by hot gluing the turn lights into the pen, so that they will be water tight. After that dries glue the pen halve over the holes you cut for the wires to run to the inside of the box. Now glue the four leds into their holes. After the Leds are in place and the glue has dried, carefully glue the slide switch into place making sure that the switch has enough room to turn on and off. Once everything is glued on screw the cover in place.
Step 7: Now Solder the Toggle Switches
After everything is hot glued in place take the wires for the turn lights and solder the switches in place. Also to prep the switches to be placed on the handle bars, take 4 mini zip-ties and loop one under the little tab used to keep the switch straight. in this zip-tie place a second one which will hold the switch to the handle bars. Do this to both of the switches. You can see how this is done in the second picture.
Step 8: Attaching the Lights to the Bike
Thread a mini zip-tie in each holes in the aluminum plate. Now tie the ties to the under side of the seat. After the zip-ties are firmly attached to the under side of the seat take a large zip-tie and wrap it around both posts of the bike seat and attach firmly. Now attach the two toggle switches to the handle bars in a spot where they are comfortable, for me it is one on each side near the grips. Attach the 3 main wires running from the switches to the part of the frame that holds the fork in place. Now Attach the 3 wires to the seat post and then up to the front part of the under side of the seat depending on the amount of slack you have in the wires.
Step 9: Using the Lights
To use the lights you turn on the rear main lights, and when making a turn, like a car, you flick the signal switch in the way you are turning. For stopping you can also turn on both lights.
Step 10: Now Go Out, Be Safe and Have Fun
Have fun riding your bike which now sports a new light and turning signals.