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1 LED headlight, no standlight

A homemade LED headlight for a bicycle dynamo (hub generator).

Assembly methods:

There are four pieces for the lens/LED assembly:
* lens (L2 OPTX 6 degree spot beam)
* adapter (small piece of aluminum that makes the lens fit into the body of the headlight)
* LED (you can see the edge of the star there)
* heat sink.

The lens is held in place super glue to both the LED and adapter ring. The heat sink is epoxied to the LED using heat conductive epoxy.

The tail cap threads on with 24 TPI threads (cut on the lathe).

The lens assembly is a tight fit and stuck in place with thermal grease. I had to use a sharp knife to pry them apart. It would probably be easier to make the tail cap stuck in place the same way.
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The assembled headlight.  It is 1 1/8" in diameter and about 2.5" long.  One CREE XR-E LED.
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The assembled headlight. It is 1 1/8" in diameter and about 2.5" long. One CREE XR-E LED.

bicycledynamoelectronicsheadlightled

  • The assembled headlight.  It is 1 1/8" in diameter and about 2.5" long.  One CREE XR-E LED.
  • Another view of the completed headlight.
  • The emitter assembly.  This fits tightly into the front of the headlight when it is assembled and was locked in place with thermal grease (all of that white gunk).
  • Minimal electronics, just a switch and bridge rectifier.  If I use this light I'll put a capacitor there too to reduce flickering at low speeds.  I broke the ground wire when disassembling, oops!
  • The main body tube.  The back is threaded for the tailcap.
  • The tailcap.  It has two holes, one in the center for the switch and one for the power wire.  I'll probably cut this down to just have a few threads, it doesn't need this many.
  • The mount.  This started as a seat collar.  I machined out excess metal to bring the weight down from 30 grams to 15 grams.
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