Notes on the Bike Lamp Enclosure

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The enclosure's design is taken from http://bikeled.org/. His design, built from 1" aluminum tubing, is pretty much perfect and I don't think I could have come up with something close. It's also very well documented. I did however added a small visor over the LEDs and use a different mounting mechanism. The downside of this design is that is requires a lot of filing and sanding... It takes about 6~7h to build the enclosure. A cast-aluminum casing would be better for a production run. Still, this enclosure is weather proof and also acts as a heat sink for the LEDs. The light needed to be handle bar mounted and easily removable so I could take it with me when I park the bicycle. I used a reflector bracket as a base, two bolts and one nut. One bolt is glued from inside and pokes out, the nut is also glued inside with the last bolt screwed in with a dip of JB Weld on the end to prevent it from coming out. One of the two holes on the bracket has been cut out on one side. To remove the light you unscrew the bolt just enough to release the bracket and then twist and pull. It's a little hard to explain, look at the photos to have a better idea.

Bracket and bolts

Push

Twist & Lock

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