I did it! I have finally put together what I am calling version 1.0 of my lights. Most of these images are a little dark, but you should be able to see the important bits.

First image:


This shows the back assembly with the lights on it. I used some maple that I had lying around the shop for the mounting assembly, and attached it to my rack using wire strung over the cross struts on the rack, down through the maple, and twisted underneath. I don't recommend this mounting method, and I expect that version 1.01 will feature an improved mounting. You can also see in this image the grey electrical box I used for the rear connections. The lights are off in this picture.

Second image:


This is a better image of the mounting, showing the maple runners and the wiring more clearly. You can also see the 4"x4" box for rear connections much better - about $7.50 at the BORG[1]. It is the one with no ports or knockouts for conduit. I drilled holes for the wires where I need them just large enough for the wire in question to slip through.

Inside the box (that I am not going to show you, on account of the mess it currently is) is the terminal strip to make the various connections (battery to fuse; fuse to main power; main power to front, beehive tail light, and main tail light; brake light power to brake; returns to battery).

Third image:


Here is the front connections box. Not used much right now, but I have plans to fill it up. Right now it houses main power to brake switches and brake switches to back. Running between the boxes is a seven wire cable, which I have plans to fill, but haven't gotten to do so yet. The cable should be available by the foot at your local BORG for a little over fifty cents a foot.

Fourth image:


This may be the most interesting bit in this system. Shown is the rear brake light switch. The switch used is the SPDT roller lever switch available at Radio Shack, and probably any electronics supplier better than Radio Shack.

I mounted it by drilling through my solid aluminium brake lever with a #47 bit and threading it to #3-48. I also threaded the mounting hole in the switch (if it wasn't designed for a #3 screw, I would be rather surprised) and used the only #3-48 machine screw I could get hold of to attach it. This is also repeated for the front brake.

More pictures (particularly of the lights on) in the next post.

Tor

[1]BORG = Big Orange Retail Giant = Home Depot