I was given some Bamboo by a neighbor who considers it a weed. First thing I did was find a section with an interior large enough a Fraen lens and holder would fit. I found one and cut it slightly longer than 2 inches. I then measured another section that would tightly fit inside and cut a narrow section about 1/8 inch. I used some glue to hold it tightly in place. this would become a stop for the lens. Here are a couple of photos ready for the copper heat sink, LED, and Lens.
I cut some clear plastic to protect the lens. A little glue holds it and seals the front.
I already had the Lens, LED, and heat sink.
A bit of toilet paper cardboard wrapped and taped around the lens holder prevents rattling.
Lens, LED, and Heat sink slides right in.
Front of headlight.
A little weather sealing RTV around the edge of the heat sink will keep the LED assembly firmly in place which I will apply later.