One scrap of polyethylene pipe, one bungee cord from a tarp tent, an inexpensive flashlight, and ten minutes of your time makes a neat bike light and handlebar-mounting system.
Easily installed and removed, easily transferred to other bikes, easy to adjust up/down while riding, lightweight, and inexpensive.
Useful to light the road close-in, or to be seen by others at dawn or dusk, or to use as a backup for your main night lighting system.
Acknowledgement: This design was totally inspired by the sleek and sexy Dinotte 200 lighting system http://www.dinottelighting.com
Step 1: Parts and Tools
Ball bungee cord for tarp tent (purchased at a flea market)
Flashight, 9-LED, 3xAAA, on/off pushbutton on rear, 1" (25mm) diameter (purchased at a home improvement warehouse on Black Friday for $1.66 including batteries)
Polyethylene pipe to match diameter of flashlight, 1" dia, thinwall, 160psi (scrap from another project, originally purchased from home improvement warehouse in giant coil)
Safety glasses and sharp utility knife. (bandsaw with fine blade optional)
Step 2: Fabrication
1) Cut plastic pipe to approximate length of flashlight.
2) Cut two slots crosswise in the pipe to constrain the bungee.
3) Cut pipe lengthwise so that a small gap remains when flashlight is inserted. This allows the bungee to squeeze both the pipe and the flashlight.
4) Insert flashlight into pipe.
- You will slip with the knife. Don't put your skin in the blade's path.
- You may break a blade tip. Always wear safety glasses. (Don't ask.)
- No dimensions are critical.
- If your handlebars are not quite perpendicular to the direction of bike travel, you can cut the crosswise slots at a slight angle to make the light point forward.
Step 3: Installation
Hold assembly under handlebars with slots down. Wrap bungee cord over handlebars and under assembly. Ensure bungee rides in both slots.
My bungee cord is longer than needed, so I usually wrap it twice on one end of the light. Alternatively, you may shorten the length of the bungee cord by tying a new knot inside the ball.
I usually wrap it so the bungee ball is less visible.
That's it. Enjoy.