How to Make High Power LED Headlight for Bicycle

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It is always convenient to have a bright light while riding bicycle at night for clear vision and safety. It also caution others in dark places and avoid accidents. So in this instructable I will demonstrate how to build and install a 100 watt LED projector Headlight similar to ones that you find in Modern Motor cycles. I have installed this in my bicycle and have been using this for a couple of months now. And the best part is it is very easy to make and does not include any fancy tools.

Please watch the following video for easy understanding.

Step 1: List of Materials

  1. 20 to 100 Watt LED Chip 12V
  2. 60 degree LENS + Reflector
  3. Heat Sink 100x100mm
  4. Li-po battery 3s (drone Battery)
  5. Switch
  6. XT 60 Connector
  7. 2-Part Epoxy Glue (Araldite)
  8. Wires- 1.5 sq.mm
  9. Zip-Ties
  10. Soldering Kit(Iron,Flux,Solder,etc)
  11. Basic Tools (Drill,Nut-bolt,Screwdriver,Clamps,pliers, etc)
  12. Heat Sink Paste

Step 2: Heat-sink and Fitting the LENS

Mark the appropriate place for the holes on the heat-sink and using a hand drill make holes. Apply heat sink paste and place the LED chip on the heat-sink.

Prepare the Epoxy glue by mixing the 2 parts in 1:1 ratio. Using a tooth pick apply the glue mixture on the reflector, LED and LENS.

Place the Reflector and LENS on the LED carefully and let it dry overnight.(Cure time depends on type of epoxy)

Then cut holes to fit the switch. The position of the switch depends on your preference.

Step 3: Electrical Connections

Apply Flux to ends of the wires and tin the ends using the soldering iron. Follow the circuit diagram for connections. The polarity of the LED is important.

Make sure to insulate all the connections using insulation tape or heat-shrink tube.

Note: Do not short circuit the Battery which is very Dangerous

Connect the Bullet connectors or XT60 connectors to the LED terminals and connect the Battery.

Safety Equipment: Connect a 10A fuse in Series with the battery and connect the Ground of battery to the Body of bicycle to avoid any electrostatic shock. Also a Battery Management System(BMS) can be used with the Battery for protection.

Step 4: Install on the Bicycle and Testing

Use a small clamp and nut-bolt to fit the LED-Assembly on the Bicycle. The battery can be placed under the seat but i chose to place it on the frame. Use Zip-ties to hold all the wires and batteries in place. You might want to place the switch on the handle for easy access.

It is important to have sufficient size heat-sink for cooling the LED.A fan can also be installed for better performance. Also since the LED is high power the battery didn't last long, so it is better to have 2 batteries or use a smaller wattage LED as i did later on. So I later installed a 50 watt led.

Therefore this was a easy build and took me about 2 hours to complete. Please feel free to leave a comment below if you have any suggestions or queries.

Thank you

HS Sandesh

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    2 Discussions

    Respectfully, is a bike light ever TOO bright?

    Several years ago I was returning home at night on my favorite bike path (no cars, and the path was about half the width of a single car lane.) I was using a standard LED bike light (powered by 2 AA batteries) which was aimed down at the path about 20 feet in front of me. (Good ground illumination at the spot, yet enough spillover to be able to see outside the spot.) An oncoming biker was approaching me at a high rate of speed. His motorcycle-style light, aimed directly into my eyes, was extremely bright. So bright, in fact, that it blinded me temporarily so I pulled over to the right, stopped and got off my bike. (I'm embarrassed to admit that some angry words were exchanged.) Somewhat dazed, I waited until I got some night vision back before continuing.

    Please consider that when it comes to the intensity of light and sound, more is not always better.

    1 reply

    This is a good Instructable, but I totally agree with what you are saying. I have two main lights driven off my electric bike battery, one which is very bright for off road, one which is a joy to ride with, one which points down to the ground and just gives enough to ride by. I use a motorcycle handlebar switch so I can easily flick between them and use the dim/dip one when passing either walkers or other cyclists. I also have a road light which is bright enough to be seen by but not blinding to other road users.
    Sadly, I think some riders have a "my light is brighter than yours" mentality.