Cycling and bicycle discussion forums. 
   Click here to join our community Log in to access your Control Panel  


Go Back   > >

Electronics, Lighting, & Gadgets HRM, GPS, MP3, HID. Whether it's got an acronym or not, here's where you'll find discussions on all sorts of tools, toys and gadgets.

Reply
 
Thread Tools Search this Thread
Old 07-22-08, 02:04 PM   #1
johnthemeasurer
Johnthemeasurer
Thread Starter
 
Join Date: Jul 2007
Location: DC
Bikes:
Posts: 5
Housing for DX R2 Drop in ??

I recently got the DX R2 drop in (SKU 11836) and I love it! Very bright, nice color, etc at ~4.8 volts (4 NImh AAs). My dilemma is that I can't figure out a decent housing (I don't have any machining equipment and wouldn't know what to do with it if I did. The best I can come up with at present is metal conduit (for electrical) and that's ok, but it's heavier than I'd like. The unit doesn't fit into 1" copper tubing (it's close...) Any ideas out there? I'd like to make it into a helmet light but even a handlebar headlight would be ok.
johnthemeasurer is offline   Reply With Quote
Old 07-23-08, 11:05 PM   #2
Nouia
/\/\ \/\/
 
Nouia's Avatar
 
Join Date: Oct 2006
Location: Nope
Bikes: 2007 Trek 6000, others
Posts: 274
I've been thinking about this too. One of the ideas I had was to trim off the springs on the drop-in and solder your wire leads from the battery directly to the appropriate contacts on the drop-in (the stumps of the springs). Then dip the rig (with the open end of the reflector covered) into a jar of Plasti-Dip and the being done with it. Mounting would be done via a pair of Plasti-Dip'ed hose clamps. The leads from the battery pack can be as long as you'd want, so the battery pack would be frame/backpack mounted.

The only real problem I foresee is heat-sinking it, but those drop-ins have a lot of heavy brass in them and the wind will be flowing over the exposed reflector/LED in the front so it may be ok.
Nouia is offline   Reply With Quote
Old 07-24-08, 08:45 AM   #3
johnthemeasurer
Johnthemeasurer
Thread Starter
 
Join Date: Jul 2007
Location: DC
Bikes:
Posts: 5
Quote:
Originally Posted by Nouia View Post
I've been thinking about this too. One of the ideas I had was to trim off the springs on the drop-in and solder your wire leads from the battery directly to the appropriate contacts on the drop-in (the stumps of the springs).
That's how I attached my wires also; though I'm holding open the option of soldering the one wire to the housing (if I use copper).


Quote:
Originally Posted by Nouia View Post
Then dip the rig (with the open end of the reflector covered) into a jar of Plasti-Dip and the being done with it. Mounting would be done via a pair of Plasti-Dip'ed hose clamps.
I hadn't thought about the Plasti-Dip angle - thanks


Quote:
Originally Posted by Nouia View Post
The only real problem I foresee is heat-sinking it, but those drop-ins have a lot of heavy brass in them and the wind will be flowing over the exposed reflector/LED in the front so it may be ok.
I noticed it develops a decent amount of heat at ~4.8V (a lot less with ~3.6 or 3 NiMH AAs but noticeably dimmer - although maybe still bright enough - I may experiment here). So if I go with 4 AAs I think I'd prefer an actual housing of some sort for heat dissipation, though that may not be necessary since I'll be using it this fall and winter.

This weekend I'm going to experiment with 1" copper tubing connecters. If I get anywhere I'll post next week.
johnthemeasurer is offline   Reply With Quote
Old 07-24-08, 06:28 PM   #4
ellerbro
Senior Member
 
Join Date: Apr 2007
Bikes:
Posts: 130
Read through the reviews and discussion forum at the bottom of the product page on the DX website. There are many drop-in hosts listed by various people.
ellerbro is offline   Reply With Quote
Old 07-26-08, 03:25 PM   #5
chewybrian 
"Florida Man"
 
chewybrian's Avatar
 
Join Date: Mar 2008
Location: East Florida
Bikes: '66 Raleigh Superbe, 80 Nishiki Maxima, 07 Gary Fisher Utopia, 09 Surly LHT
Posts: 1,542
I had the same issue. I used a copper coupling to house #11621 (same drop in with a Q5 emitter). It is too big for 1" copper tubing, and too small for the coupling, but... a piece of cpvc pipe (3/4", I think) fits snug inside the coupling, and insulates the drop-in from the copper. Mine is sealed in silicone behind a lexan plug(easily cut with a hole saw and a drill press). I soldered the power wires direct to the drop-in, and buried them in silicone as well. I have yet to notice any heat build up issues. Maybe I am shortening the life of the emitter, but no issues that I can see yet.

I strapped 3 of these together, and angled them out slightly to get a wider patch of light. I power it with 8 nimh AA's--lights are parallel, batteries in series. It goes a bit over 2 hours, and provides a very useful light. When I get a camera, I will post a bike light vs. car light shot.
chewybrian is offline   Reply With Quote
Old 07-26-08, 07:57 PM   #6
Nouia
/\/\ \/\/
 
Nouia's Avatar
 
Join Date: Oct 2006
Location: Nope
Bikes: 2007 Trek 6000, others
Posts: 274
Quote:
Originally Posted by chewybrian View Post
I had the same issue. I used a copper coupling to house #11621 (same drop in with a Q5 emitter). It is too big for 1" copper tubing, and too small for the coupling, but... a piece of cpvc pipe (3/4", I think) fits snug inside the coupling, and insulates the drop-in from the copper. Mine is sealed in silicone behind a lexan plug(easily cut with a hole saw and a drill press). I soldered the power wires direct to the drop-in, and buried them in silicone as well. I have yet to notice any heat build up issues. Maybe I am shortening the life of the emitter, but no issues that I can see yet.

I strapped 3 of these together, and angled them out slightly to get a wider patch of light. I power it with 8 nimh AA's--lights are parallel, batteries in series. It goes a bit over 2 hours, and provides a very useful light. When I get a camera, I will post a bike light vs. car light shot.
Get a camera quick, man, I'm very interested in seeing this, both beamshots and the lights themselves. Sounds pretty solid.
Nouia is offline   Reply With Quote
Reply


Thread Tools Search this Thread
Search this Thread:

Advanced Search

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off



All times are GMT -6. The time now is 07:29 AM.