How to Build a Halogen Bike Light

How to Build a Halogen Bike Light
Night riding is an enjoyable and thrilling way to get around. You develop a new feel for your mountain bike not seeing each and every bump in the trail. Even so, this does require a solid light to illuminate the trail, or if you are riding as a commuter you need to let cars know where you are. You can fashion a solid and working halogen bike light that will successfully address both of these scenarios.


Difficulty: Easy

Step 1
Cut down the discarded halogen flashlight handle to a length of 6 inches using the handsaw. Smooth the edges with the sandpaper. Make sure the battery cap is screwed firmly into the end of the tube.
Step 2
Place the 10W halogen bulb into the reflector housing. Snap the bulb into position and set the unit aside. Cut a round piece of the perf board, the same diameter as the inside of the cut-down flashlight tube. Remove the wires from the light kit.
Step 3
Thread the wires from the lighting kit through the perf board. Attach the metal tongue to the perf board and attach the wires to the tongue ends. The perf board should look like a small plastic cylinder with two wires sticking through, attached to the small silver tongue from the light kit.
Step 4
Slide the wires through the tube. Unscrew the end cap and make sure the wires come through the end. Run the wires into the 3.5Ah 7.2V lithium ion battery pack and attach the red wire to the red/positive terminal at the pack and the black wire to the black/negative terminal on the 3.5Ah 7.2V lithium ion battery pack. Fill the remainder of the tube with Styrofoam peanuts to prevent the wires from moving. Duct tape the end of the tube leaving the wires to hang out and be attached to the 3.5Ah 7.2V lithium ion battery pack.
Step 5
Attach the C-clamp screw attachments to one side of the handlebars on the bicycle. Attach the receiving end of the C-clamp attachment to the bike light tube. Attach so the tube light is on the top of the handlebars and the light structure is facing the front tire.
Step 6
Slide the halogen light bulb and reflector into the tube housing and secure with duct tape so the light bulb is exposed and the reflector is not covered by the duct tape.

Article Written By Eric Cedric

A former Alaskan of 20 years, Eric Cedric now resides in California. He's published in "Outside" and "Backpacker" and has written a book on life in small-town Alaska, "North by Southeast." Cedric was a professional mountain guide and backcountry expedition leader for 18 years. He worked in Russia, Iceland, Greece, Turkey and Belize. Cedric attended Syracuse University and is a private pilot.

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