Modify a solar garden walkway light into a solar powered bike light that charges during day riding and can be turned on at night!
Step 1: Obtain Materials
1. Solar Garden Light (G15439)
2. LED Lamp, from flashlight, I used (G15654)
4. Wire, solder, etc
5. Tools, drill, knife, screwdriver
1 and 2 have part numbers from the electronic goldmine.
Step 2: Take Apart the Solar Lamp
This should come naturally to most people here :)
There are 3 screws holding the 2 halves of electronics enclosure together, the transparent dome pops off easily.
Step 3: Add Your Lamp in Place of Exsisting LED
Using a soldering iron, de-solder the exsisting LED on the lamp and put it in your parts drawer/box/floor.
Be sure you have the polarity correct when you solder the leads of your lamp to the leads where the first LED used to be!
I covered the soldered connections in hot glue after I was done.
Step 4: Expand/Add Hole for Mounting to Bike
Using a drill I expanded one of the holes in the plastic that held the solar panel. This let me mount the unit where my reflector used to be.
Step 5: Cut and Epoxy Lamp to Solar Lamp Unit
I had to use a knife to expand the hole opposite of the mounting hole we drilled in the last step.
I set the lip of the lamp into the notch and epoxied it there, I also added epoxy to secure the wires and the LED's PCB.
Step 6: Mount to Your Bike!
I was able to mount this by removing the reflector and just using the same screw and mounting plastic.
Use a screwdriver to tighten and loosen things and position the lamp to your liking. I found that when riding, the circuit turns off the light when under a street lamp.
Have fun, be safe, wear a helmet yada yada...