Broken Bike Light - Giving a New Life




One evening I had a bumpy ride on my bicycle from office back home. My brand new front light slipped from its groove, fell on the road and came under a motor bike, it just couldn't take the ride anymore....

From a distance I could see lots of crushed pieces on the road and thought that poor gadget is finished. Just then I thought I should go closer and assess the damage. When I had a closer look I could see that the outer casing of the LED unit, the front glass was fully damaged and the battery holder casing damaged to an extent. The actual LED and the battery holder units were lucky, had survived with only minor bruises.

Not knowing what to do with those units I just picked and brought them home. Since then I have been thinking on ways to use them, but nothing came to my mind. One fine day I thought why shouldn't I try and rebuild this front light.????

Here I am going to show you how I was able to give a new life to my bike light.

Step 1: Things Needed


- Salvaged front lamp units [LED, Battery Casing & Holder]
- Free hanging bulb holder
- Cycle handle clamp
- Small Measuring Cup [comes with medicinal syrup bottles]
- Insulated wire
- Power connectors
- Plastic/Rubber Washer
- Adhesive [Fevibond/ Superglue etc]
- Padding [Foam/ Styrofoam]
- Insulating tape
- Cling film

 - Screwdrivers
 - Solder Gun
 - Solder Wire

Step 2: Finding Casing for LEDs - a Story

Finding the right components is key to any project. In this case I wanted something that could hold the LED unit in place. I started my search from the local hardware stores. But wasn't sure what to ask for, maybe - pipe pieces, curtain rod holders etc. I also tried with few thing that were lying around in the house - small bottles, small measuring cups/caps etc. Somehow all these items were not appealing and did not fit in the design [which did not exist]. I just dumped all these items in my junk box and kept my search on....

One day I realized that one of the bulbs in the stairway had fused. When I was replacing that bulb my attention went to the bulb holder, especially towards the casing which surrounded the bulb holder. I removed the casing and immediately went up to pull the salvaged items from the box. I popped the measuring cup and the LED unit  into this casing and EUREKA [i shouted like how Archimedes would have then] my project blue print was almost ready.

Step 3: Wire Up LED Unit

- Pickup the LED unit and remove the back lid by unscrewing tiny screws
- Pickup 2 insulated wires and solder one each to the 'positive' and the 'negative' leads
- Take these wires out through the lid and from the same holes meant for the +ve and -ve leads. Note that one has to press this lid a little as there is hardly any space
- Put the screws back and tighten-up

Step 4: Building Front Casing

I have used medicinal syrup measuring cup to hold the LED unit. This is a nice fit for the LED unit. However, there is a little gap between the LED unit and the cup walls which needs to be filed in. I have used foam to fill this gap and absorbed the shocks on the LED unit during travel

- Cut 4 small pieces of the foam
- Stick them inside on the cup walls
- Gently place the LED unit inside the cup
- Pick the lamp holder and open out completely by unscrewing the front and rare casings
- Discard the center unit
- Pick the front casing from the dismantled lamp holder and apply some adhesive to the inside rim
- Stick the measuring cup [now holding the LED unit] on this casing rim
- Allow it to dry

Step 5: Building the Rare Casing

- Pick the rare lamp casing and drill a hole. This hole should be big enough to fit the handle clamp screw [As I don't have the drill I I got this done from a local hardware shop]
- Attach this casing to the clamp using the screw, washer and the nut

Step 6: Putting the Front and Rare Casing Together

- Take the loose ends of the wires out from the center hole of the rare casing of the lamp
- Push some foam pieces into the hollow space of the rare casing to ensure the LED unit does not fall back
- Using adhesive stick the front and rare casing together
- Allow it to dry

Step 7: Adding Power Connectors to the Lamp

- Attach the loose ends of the wires to the connector leads
- Attach the leads to the male connector
- Using insulating tape hold the wires together

Step 8: Wire Up Battery Holder

- Pickup the battery unit and removed the top lid by unscrewing tiny screws
- Pickup 2 insulated wires and solder one each to the 'positive' and the 'negative' leads
- Take these wires out through the lid and from the same holes meant for the +ve and -ve leads. This time there is just enough space for the wires to come out
- Put the screws back and tighten-up
- Wrap the cling film to add some basic water proofing

Step 9: Adding Power Connectors to the Battery Holder

- Attach the loose ends of the wires to the connector leads
- Attach the leads to the female connector
- Using insulating tape hold the wires together

Step 10: Mount the Lamp

- Pick a spot on the handle and attach the lamp/clamp there. Just ensure that this spot is parallel to the ground
- Loosen out the other clamp and tilt it such that it will hold the battery casing upright when attached
- Attach the battery casing on the clamp
- Add 4 AAA batteries and place the battery holder unit into the battery casing
- Connect and male-female power connector

Hurray! My front lamp is back in action.

Step 11: Road Test

1. While I was coming back from office there was light rain and I realized that the battery unit lacked any kind of water proofing.  On reaching home first thing I did was to add some basic water proofing. I wrapped the battery holder unit in a cling film. This should take care of the occasional rains, a trend in this part of the world

2. Due to the plastic cup covering the LED unit, there is reduced light on-the-street. I felt this is another disadvantage. However, I feel there is enough illumination for the oncoming traffic to spot my bike, which should work in my favor!



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    3 Discussions


    1 year ago

    Good one!


    7 years ago on Step 11

    Awesome. Thanks for sharing this.