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Old 08-28-10, 09:42 PM   #1
shuttervox
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My Steampunk style headlight & mount, with DIY instructions

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My '85 Peugeot PH11 headlight setup:



(BTW, the bell is a "tangerine" Incredibell JelliBell)

To make this, you will need:

--- A polished stainless steel or aluminium led flashlight.

I used a Ese LZ2 Stainless Steel 1AA LED flashlight, which is no longer in production.

The "Ultrafire C3 CREE Q5 Stainless Steel" is similar, and can be found on ebay for $21.99
(edit: or here for $13.95, free shipping)

Also awesome would be the iTP A2 (or A1) EOS SS, widely available for around $32, or any number of other stainless steel flashlights. For more ideas check out this candlepowerforums thread

A polished aluminium flashlight would also work, but they seem to be hard to find.

WARNING: Stainless steel is heavy, due to its high awesome content. Weight weenies beware.



--- A copper "Milford" type pipe hanger. They look like this:



I found mine at Lowes.

--- An appropriately sized hose clamp, classic worm gear style. Also from Lowes.
(Note: There may be a snazzier alternative, perhaps some form of copper band, but this was the first thing that came to mind)

--- Felt. I used a very high quality dense felt used in piano restoration, but any sort of soft thick fabric, leather, or rubber would work.

Here is a better view of the construction:



-- If increased strength is desired, solder the joint in the milford hanger (it was wiggly on mine). If solder is not possible, I think epoxy would work. Solder is recommended.

-- Line the inside of the pipe hanger and hose clamp with slightly oversized felt- I used 3M Super 77 Spray Adhesive. Trim edges with razor blade.

-- Bend strap of Milford hanger approximately 1/2" below joint. I used vice-grip needle nosed pliers to grip as close to the curved clamp part as possible, and bent using the leverage of the strap.

Note: if you use a larger diameter flashlight, or one without the "hourglass" shape, you may need to make the bend farther from the clamp to provide adequate clearance. Or, spin hose clamp so the screw/gear is out of the way.

-- Trim strap of Milford hanger to desired length.

-- Affix hose clamp to top of handlebar stem.

-- Slide Milford clamp strap between hose clamp and felt, so when the hose clamp is tightened it does not scratch the stem.

-- Tighten hose clamp, insert flashlight into Milford hanger clamp and tighten screws.


Note: correct size of Milford clamp and hose clamp will vary depending on flashlight and handlebar stem size respectively


I will try and answer any questions, and feel free to offer suggestions for improvement!




[k]

Last edited by shuttervox; 08-29-10 at 01:02 AM.
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Old 08-28-10, 10:02 PM   #2
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I'll have to try that. It looks awesome! How much light output are you finding with the flashlight? Also, what kind of bar tape is that? I'd guess shellacked cork, but it doesn't look fat enough for that...leather?
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Old 08-28-10, 11:49 PM   #3
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How much light output are you finding with the flashlight?
I find it to be blindingly bright, especially in comparison to bicycle specific headlights. These modern "tactical" type flashlights are pretty impressive. It casts a nice even pool of light makes riding at night easy, even with no street lamps.

Of course, you pay for that with battery life... at it max setting, it lasts a little over an hour. I tend to use the medium setting, and get more like 2 hours. Low setting lasts around 6hrs. I use Sanyo Eneloop rechargeable AAs, and just put in a freshly charged one before every night ride.

(full review here for flashlight geeks)

Cat Eye type "headlights" last like... 100+ hours, but there is no free lunch. All LEDs are pretty efficient, so anything that is going to actually make the road visible is going to be pretty expensive energy wise. As far as I am concerned, bicycle specific headlights are just blinky white lights that inform cars which end of you they just ran into


Quote:
Also, what kind of bar tape is that?
Cinelli natural/tan cork tape, 6 coats of Bulls Eye amber shellac. The "fatness" of cork tape really depends on the amount of overlap while wrapping, and I went with just enough overlap to hit the previous edge with the line of adhesive. Copper wire wrap on ends.

Here is a better shot of the bar tape:




[k]

Last edited by shuttervox; 08-28-10 at 11:57 PM.
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Old 08-29-10, 12:05 AM   #4
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I can see this being mounted under the stem at the clamp nut with no need for a pipe clamp... such a wonderful solution as it uses something that is so commonly available.

If the strap was long enough one could even do a fork mount... lowering the light makes it much more effective.

And stainless steel is full of awesome.
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Old 08-29-10, 12:24 AM   #5
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I can see this being mounted under the stem at the clamp nut with no need for a pipe clamp...

Oh, you mean attaching the Milford hanger directly on the stem clamp bolt, and then bending the strap to whatever angle needed? That's brilliant! I'll grab another hanger next trip to the hardware store and try it out. Do many stems have that bolt in a similar place and angle?

Quote:
If the strap was long enough one could even do a fork mount...
Wait, how would that work? I'm having trouble picturing it.



[k]

Last edited by shuttervox; 08-29-10 at 12:35 AM.
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Old 08-29-10, 01:15 AM   #6
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Quote:
Originally Posted by shuttervox View Post
Oh, you mean attaching the Milford hanger directly on the stem clamp bolt, and then bending the strap to whatever angle needed? That's brilliant! I'll grab another hanger next trip to the hardware store and try it out. Do many stems have that bolt in a similar place and angle?

Wait, how would that work? I'm having trouble picturing it.

[k]
Many old quill stems would have a reflector mounted at the stem nut, these were often secured with a second nut of the stem bolt was long enough.

A fork mount would require the strap to keep it's bend under the light and the remaining strap would have to be wrapped around the fork leg and secured... this should be pretty easy and I will be popping by the hardware store tomorrow for some of these straps.

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Old 08-29-10, 07:35 AM   #7
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Thats a nice looking setup. You can mount that so many different ways. One that might work well is to mount it with the brake caliper bolt like a reflector mount. That'd probably be better with fenders if the clamp strapping doesn't have the strength to keep the light from bouncing up and down and then catching the wheel. Thanks for sharing this, I've got some cheap harbor freight led flashlights that I've been thinking about mounting, now I know I need to get a Milford clamp and put those puppies on there.
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Old 08-29-10, 09:10 AM   #8
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A little bit off topic, but could that brass pipe hanger also be used to fashion a handlebar or stem mounted bracket for a water bottle cage?
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Old 08-29-10, 10:13 AM   #9
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2 hose clamps and a $2 led light



been doing them like this for a few years now - it works and it's cheap!




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Old 08-29-10, 03:23 PM   #10
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Perhaps a copper bell would be a finishing touch:

http://store.somafab.com/sucrbeinco.html

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Old 08-29-10, 05:18 PM   #11
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Quote:
Originally Posted by gbalke View Post
A little bit off topic, but could that brass pipe hanger also be used to fashion a handlebar or stem mounted bracket for a water bottle cage?
You probably could, but why would you? You can get them new.
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Old 03-03-13, 12:50 AM   #12
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I know this thread is ancient now, but I found this post while searching for "Retro DIY Bike Light." Amazing how few alternatives there are being produced... it's an untapped market. I really like the look of this light and mount. I even found the same out-of-production "Ese LZ2 Stainless Steel 1AA LED flashlight" as the OP here - http://www.goodluckbuy.com/ese-lz2-s...ight-1aa-.html

I am heading to Lowe's to pick up that Milford hanger soon. Anyone have any ideas on mounting other than the OP? Since I don't have any power tools besides a drill, I'm hoping I won't need to solder or cut any metal.

If anyone's interested, I did see another very enticing Dynamo here called the Lumotec Classic (you have to scroll way down or CTRL-F): http://www.peterwhitecycles.com/b&m-hl.asp
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Old 03-03-13, 03:57 AM   #13
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Originally Posted by warrennnnnnnnnn View Post
I am heading to Lowe's to pick up that Milford hanger soon. Anyone have any ideas on mounting other than the OP? Since I don't have any power tools besides a drill, I'm hoping I won't need to solder or cut any metal.
I would try to attach the hanger at the handlebar pinch bolt. Maybe in place of the washer? No need for a hose clamp that way. You'd have to do a different bend, and find a hanger with an appropriate hole of course.
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Old 03-03-13, 06:19 AM   #14
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If you really want retro you need these






IMHO if your going to use a flashlight for a headlight get a real flashlight like a Surefire or similar quality light
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Old 03-12-13, 07:48 PM   #15
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Wow, big letdown on the ESE LZ2 Shiny Stainless Steel flashlight so far. I bought from GoodLuckBuy.com and it is non-functioning. I tried new battery after new battery and it would not turn on. I checked for paper or plastic in it to peel off and there is only the bare battery compartment inside. We'll see how they handle this one.

GoodLuckBuy is international, so I waited weeks too...
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Old 03-12-13, 07:48 PM   #16
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I would try to attach the hanger at the handlebar pinch bolt. Maybe in place of the washer? No need for a hose clamp that way. You'd have to do a different bend, and find a hanger with an appropriate hole of course.
The pinch bolt was way too big for the Milford hanger. There would have been no hanger left if I drilled the hanger to fit the size of the handlebar pinch bolt.
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Old 03-12-13, 08:44 PM   #17
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Not steampunk but its what I made. Its a regular dollar store LED flashlight with a mounting bracket I put together out of spare parts.




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Old 09-22-13, 05:16 PM   #18
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So everything turned out well with GoodLuckBuy for this out-of-production flashlight. Never figured out why it wasn't working with me, but they gave me a battery and tested it, told me it worked fine, so there was no replacement necessary. They shipped it back to me and now I'm very pleased with it.

My 1981 Univega Sportour (that's a Minoura smartphone mount on the left):

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Old 09-22-13, 05:32 PM   #19
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If you think hose clamps are a bit primitive, you might give stainless Pex clamps a try. You'll need a crimp tool to use them.
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Old 09-27-13, 01:09 AM   #20
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Wow, so I finally figured out why the light wasn't working for me initially. ATTENTION, all people attempting this flashlight/mount idea: this flashlight, if you buy it from GoodLuckBuy (which is the only place I could find this, since it was out of production), does not take typical AA batteries. It takes the 14500 type battery.

For those who don't know, 14500 batteries are AA-sized, lend way more brightness than AA in flashlight applications, and run at a higher voltage.
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Old 09-27-13, 06:46 AM   #21
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If you truly want a Steampunk look, need to build up a Carbide Headlight system...:-) Keeping it from blowing out at speed would take some work, and they DO get hot.

https://www.lehmans.com/p-1559-carbi...t-striker.aspx
antique one on a bike...COOL!!
http://www.flyingpigeonproject.org/2...lar-power.html
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Old 09-27-13, 01:06 PM   #22
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Brings back commuting memories from the 70's. I used carbide lamps on my bike for years, however the repulsive stench of wet carbide is quite gross!! Mine did occasionally blow out until I cut a small section of auto headlight glass with vent for a lens. They were extremely bright.
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Old 09-28-13, 07:45 AM   #23
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Not at all steampunk, nor C&V, but this is my flashlight turned headlight setup on one of my wife's city bikes. The bottle dynamo still powers the stock headlight, but the battery flashlight on teh fork leg serves as a backup:

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