Scratch built SSC P7 bike lights - page 1 |
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This is one of my ideas for super lightweight and super small SSC P7 900 lumen Bike light. I have built and tested several of these P7 lights. I have been using 2400mah 3.6v Lithium Ion batteries that have been assembled into battery packs with all the batteries soldered into a parallel arrangement I have some nice battery chargers that will charge up to about 15000mah battery packs. So I can actually add as many batteries to the packs as I need for whatever run time I need. 3 to 4 x 2400mah Li-On batteries in a pack seems to be working out great for my needs. The high temp plastic mount is designed to work with Marwi handlebar and helmet mounts. The Marwi mounts are awesome and the price is reasonable and so there is no need for me to design a mounting system. See this page for more info on Marwi mounts. |
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The lights are only 54mm long x 25mm wide at the switch end x 35mm wide at the business end. The assembled light below weighs only 65 grams which is way lighter than any of my previous lights. The LED capsule/Heat sink fits snug inside the outer casing and transfers the heat away from the LED assembly. All aluminum parts are machined as thin as is possible, without being too thin, to make them heat sink more efficiently and to reduce weight without sacrificing strength. The aluminum reflector fits into the outer casing and is glued in place using high temp silicon. |
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Side View Click picture to see measurements |
Front View The glass is machined into the reflector and sealed with high temp silicon. |
Rear View Rubber switch cap and clicky switch |
| The lower light is an early prototype. It's gotten quite scratched up from all the testing, measuring, assembling and disassembling. | ||
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A bit about the design All surfaces are machined to fit snugly inside another surface. In the photo above, the main body interior has a step shape that is machined to match the shape of surface 1 and surface 2. The reflector end of the main body is machined with an angled surface so that it matches up perfectly with the shape of the reflector. The reflector is sealed in place and becomes part of the main body. The glass is machined into the front bezel of the reflector and sealed in place with high temp silicon. Surface 1 is the LED capsule. The LED is surrounded by a thin wall heat sink and transfers it's heat out to the main body and onto surface 2 Surface 1 actually sits inside surface 2 just a bit and so heat transfer occurs between these two surfaces also. There is a bit of thermal grease applied to the LED assembly to aid in the heat shedding. Surface 2 is the rear tail cap/switch body. It fits snug inside the main body also and is parts of the whole heat sink system. The reflector is made of aluminum. It is machined into the main body and is also part of the heat sinking The thickness of my capsules and casings are about 1.22mm or .048 inches thick. |
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A note about heat and other lights I own. The heat problem you get with flashlights is because they machine the bodies to be quite thick. Thicker metal holds heat longer and the heat build up can be a problem. The MTE P7 flashlight I own is not engineered very well, the LED capsule is connected to the main body by two tiny threads. There is a large air gap surrounding the LED mount, which is not a very good way to transfer heat away from the LED. I converted one of the MTE flashlights into a bike light (see my bike lights page for that project) It gets ripping hot and stays that way because the flashlight body is way too thick and other reasons mentioned above. The thick body is fine if you need to whack someone over the head with your flashlight, but it is not what you need in a bike light. My HID lights also get very hot to the touch. One of them even is enclosed in a carbon fiber tube. It looks really cool, but carbon fiber does not transfer heat very well. |
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