I broke the mounting lug on my Cyo in a minor crash, epoxied it back together, and the repair failed. Now I`m trying to work out a method to hold it by a sheet metal strap wrapped around the body and need a way to keep it from worming itself out of the strap since the body is slightly egg shaped. I think a couple of small screws through the strap and into the plastic would do the trick, but I`m concerned about drilling into the electronics inside and I have no idea where they are.
I have openned my cyo.
Remove long screw from the center of the housing, then remove heatsink and LED.
Then you can pry the reflector out of the housing.
Great photos from German MTB-forum here. I succeeded using those pictures.
Thanks guys, that`s perfect!
I did try that screw before even posting here, and it obviously loosened the heat sink, but didn`t let it go completely. Like the poster in U.H.`s linked thread, I didn`t want to force anything since my light currently lights, just needs a new mounting method.
Anyway, I got home from work this morning and internet service was out, so I screwed around and got my strap method to work, but after looking at the German pics, will try disassembling again and possibly screw in a new aluminum lug on top of the heat sink with a pair of m3 flathead screws c-sunk from the rear. If that works, it`ll be cleaner than what I have now. Will post a followup when I get it finished one way or the other.
Might even be a nice alternative for people to get Jan Hein`s top mounting eDelux at a Cyo price
Last edited by rodar y rodar; 01-04-13 at 01:20 AM.
Just for fun, here was my strap attempt: http://www.bikeforums.net/showthread...1#post15123292
I took the light apart and I`m pretty sure I see a way to screw a lug on top by tapping the hole from the "mystery screw" all the way through and adding one more small screw or pin to keep things from rotating. But that`s going to be fairly complicated, and I`m in a hurry for a different project, so the next step with the Cyo will probably be a few weeks out. I`ll post back on this thread to report how it goes.
I think I have it now. The new mounting lug is done and I had to make new brackets for the top sided lug, but it actually looks like a better position than I had it in before- less in the way now. Here`s how I did it:
Drilled and tapped the 4mm threads that the Magic Screw on the bottom goes into so that there`s a threaded hole all the way through the heat sink. Fabbed a small aluminum block with a mounting hole for 6mm bolt through the side and a seriously counterbored hole from top to bottom for a 4mm button head screw. That screw shared the same hole as the Magic Screw. Filed more heat sink and filed the bottom of the aluminum block so they match up (I didn`t do a very good job of that part, but it`ll work). Screwed the block to the heatsink and tapped a 3mm hole through the sink and into the block, put in a little screw from the inside. Took the block off again and pared down the excess material. Put it all back together with Loctite and work out the mounting. Done. Looks pretty good, eh? I just need to unwire the spare light, wire in the repaired one, and we`ll see how it lasts this time. Third time`s the charm!
Not sure I`d have done it on a light that didn`t need some kind of fixing. If you try it, after unscrewing the sliver screw to the end of its threads, you have to pull it out a little more with a small tool to move the heatsink rearward- that`s why mine didn`t come completely apart the first time I tried. Oh, and good thing I found that brazing filler cause besides the brackets I ended up putting a new boss on the rack!