The lights and toolbox combo are really a cobbling together of two ideas I found on the web. The idea for the lights came from this website: http://nordicgroup.us/s78/. He provides a ton of info on lights as well as sources for parts. I bought the battery, charger, lights and bulbs from sources he lists. To keep the price down I used a 5amp hour SLA battery that cost like $13. My switch, a fuse and some connectors came from Radio Shack. All the parts to make the lights cost me maybe $45.

The two light housing are auto driving lights that come with 55w bulbs, but they can be switched to MR16 bulbs. In one light I have a 10w narrow flood which provides enough light to be seen and to see in twilight. The other has a 20w narrow spot for riding in total darkness and is really wonderful. The lights are mounted on a piece of 1/4 UHMW plastic which is connected to the tool box with 4 nylon bolts. I think they're 1/4 in.

The toolbox is made up of corrugated plastic (sometimes called Coroplast). At this website: http://www.mile43.com/peterson/Kents_Tailbox.html you'll see some of the inspiration for my design. I worked out a pattern on some cardboard (actually 2 patterns since the first one didn't work). Once I had a working pattern I cut it out of the plastic, folded it properly and the glued things together with Superglue and then used some more nylon bolts to make sure everything stays together.

The box's lid fits pretty snugly to keep rain and spray out. Two nylon straps go around the box and the UHMW plastic base to hold the lid down and keep everything together should a glue joint or bolt fail. I mounted some velcro strips to the straps and use those to hold my minipump on top. The minpump serves as a carrying handle when I take it off the bike.

The whole rig is held on the bike with hooks bent from 3/8 PVC rods. To keep the box from swinging I bolted a strip of metal to my front brake bridge that sticks up through a slot in the back of the UHMW sheet on the bottom of the box. It takes me about 20 secs to lift it off my bike and go. I ordered the corrugated plastic, UHMW and PVC rod online through Modern Plastics. I am guessing that all of the plastic, glue, straps, etc for the box cost about $40. So for about $80 bucks I have a very bright, durable, portable light/toolbox. I haven't weighed the whole box loaded, but I would guess it is in the 7 - 9 lbs range.