DIY light projects

It was time to move from halogens to leds
Efficiency measurements 2007-10-23
Lumicycle update 1, 2007-10-24
Lumicycle update 2, new 4 mm plate, 2007-12-14
Prototype with Fraen, 2007-12-10
Dimensions, 2008-01-04
Real world comparison, 2008-01-01
Prototype 2008-10
Conclusion, 2008-09
Prototype 2009-10-22, XP-G
Lumicycle update 3, 2009-10-30, XP-Gx7
Efficiency measurements 2, 2009-11-02
Efficiency measurements 2007-10-23

I made some efficiency measurements with led-tech.de PowerLines and Bflexs:




PowerLines seems to be unefficient, bFlex-board works fine:


Lumicycle update 1, 2007-10-24

For the project I found some old copper pipe:

After some tooling and filing:

Pipe, bFlex and Cutter plate fits in Lumicycle housing but are very thight (Cree, Khatod and bFlex from www.cutter.com.au):



And with 1 amp the housing will be hot if you are not rolling...

Other people have done this update before: http://www.singletrackworld.com/forum/read.php?f=2&i=3251489&t=3251489/ If the link doesn't work, search "3xCree Lumi upgrade" at singletrackworld forum.

The original thread seems to be missing at singletrackworld, here's a little bit old pdf-copy of it.Singletrack-Cutter_3xCree_Lumi_upgrade-2.pdf

Lumicycle update 2, new 4 mm plate between Cutter leds and aluminium pipe, 2007-12-14

New plate for better heat transition:


All parts together:




New plate fits tight:

+ Lexan glass


Prototype with Fraen optics and 3 position switch for low/trail/high-lights, 2007-12-10

Fraens are for high light:


Prototype box for experimenting has one in lead from battery, leads from/to switch, out leads for always on-, low-, trail- and high-lights


The Good, the Bad and this is the Ugly one


Dimensions, 2008-01-04

Cutter plate (newer one):

Cutter optics (narrow and medium):




Plate between Cutter leds and Lumicycle housing (it fits pressed by fingers):


Real world comparison, 2008-01-01 (XR-E leds are Q5 bin)

3xCreeXR-E-1A x 2; left Khatod 8deg, right Khatod 8deg

3xCreeXR-E-1A x 2; left Cutter Narrow, right Khatod 8deg

3xCreeXR-E-1A x 2; left Cutter Medium, right Khatod 8deg

3xCreeXR-E-1A x 2; left Khatod 25deg, right Khatod 8deg

Left 20W 30deg MR11 Halogen 16V, right 3xCreeXR-E + Khatod 8deg 1A

Left 20W 24deg IRC MR16 Halogen 16V, right 3xCreeXR-E + Khatod 8deg 1A

Left 3xCreeXR-E + Khatod 8deg 1A, right 2xFraen 10deg + 1xFraen 15x24deg 1A

3xCreeXR-E, Khatod 8deg 1A

3xCreeXR-E, Cutter Narrow 1A

3xCreeXR-E, Cutter Medium 1A

3xCreeXR-E, Khatod 25deg 1A

3xCreeXR-E, 2xFraen 10deg + 1xFraen 15x24deg 1A + Aapo 4 Years

20W 30deg MR11 Halogen 16V

20W 24deg IRC MR16 Halogen 16V

3xCreeXR-E x 2 + Khatod 8deg 1A + 2xFraen 10deg + 1xFraen15x24deg, 1A

OctaviaXenon Low beam

OctaviaXenon + 9xCreeXR-E (2xKhatod 8deg + 2xFraen 10deg + 1xFraen 15x24deg) 1A

TestEquipments

OctaviaXenon & 9xCreeXR-E (2xKhatod 8deg 1A + 2xFraen 10deg + 1xFraen 15x24deg) 1A

Lenses from left: Khatod 8deg, Cutter Narrow, Cutter Medium, Khatod 25deg



Prototype 2008-10

Under Construction... Experimenting with wider and more even beam for low speed and street usage when there are oncoming cars and pedestrians.

Conclusion, 2008-09

With these leds for street (low) / trail / high (road and high speed) usage I would suggest:
- Low = 3 x Fraen 15x24 deg 1A (3 leds), 7-8deg angle between leds for wider beam
- Trail = 2 x Cutter Medium 1A (6 leds)
- High = 1 x Cutter Medium 1A + 2 Cutter Narrow (= 9 leds) or
- High = 1 x Cutter Medium 1A + 6 x Fraen 15x24 deg 1A (6 leds) (= 9 leds)


Prototype 2009-10-22, XP-G R5, 4S, bFlex


Prototype box for experimenting has one in lead from battery, leads from/to switch, out leads for always on-, low-, trail- and high-lights





Mirror plate

Beam is wide

Lumicycle update 3, 7xXP-G + maxFlex, 2009-10-30

New 8 mm plate for more poer:







Thermal compaund is applyed after the pics are shotten.


Thermal protection is set to 60 degrees Celsius. On slow speed trails at 0 degrees it can be run full a couple of minutes, after that thermal protection seems to work fine.


Efficiency measurements 2, 2009-11-02

With Taskled maxFlex & XP-G 7S & 10.4Ah/5.2Ah/2.4Ah batteries, small battery has a significant drop of voltage at higher currents:


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email: kai dot js dot nurminen at gmail dot com
No, no I'm not the icehockey player, I'm the cyclist one