Here is a instruction to construct an useful multiple handlbar bracket..AGAIN using the Cateye 533-8730 spacer and handlebar bracket.

September 27, 2004

This is a reprint of my posting back in May for a workable flashlight handlebar
mount.......

For those who have been disappointed in the past.. here is a suggestion on
constructing a handlebar bracket to secure an ordinary flashlight on the
handlebar -- similarly to what TWOFISH bracket offers but much superior and
versatile.

My flashlight of choice Princeton Tec -T40.

WARNING: NOT FOR OFF ROAD USE... plastic bracket might fail due to excess
vibration.

1. Start with a Cateye Micro 500II and handlebar bracket.

2. Remove the removable locking bracket from the underside of Cateye Micro
500II (Cateye people call this part "spacer")PART-NUMBER 533-8730..Make sure you don't lose the
internal spring mechanism for the quick release locking mechanism.

3. Find yourself a 2.5" by 5" (or comparable size of your choosing) flat
plastic or metal plate
of study construction that will hold up to road vibration.

4. Affix the locking bracket to the metal plate with a screw and locking nut.
Make sure the nut will not unscrew by road vibration. In my case, I used left
over Shoe Goo to secure the nut. Sidebar: Another good application for shoe
goo is for cable ends to prevent from wire fraying.

Since quick release bracket is fastened to the metal plate with one screw, it
is important that it is secure. Before I installed the screw and nut, I used a
small piece of two sided tape.

5. With the 2.5" x 5" plate in (computer terms - Portrait configuration, lay a
1 1/2" wide by 11" Velcro D-Ring strap across (left to right) the middle /
center of the metal plate

6. Place a two sided industrial strength 2.5" x 5" adhesive back Velcro hook
tape (same dimension as your metal plate also commonly known as hook and loop)
on top of the metal plate covering the D-ring Velcro strap -- thus securing the
strap to the metal plate.

7. With the D-Ring Velcro strap.. I can safely secure a flashlight, FRS radio,
Motorola T 6310 has a FM tuner for music), GPS unit, or my Yaesu Vertex VX-150
ham radio on the handlebar. To further enhance the contact points.. I place
two
sided adhesive Velcro loop tape on the back of my electronic devices so it
mates with the Velcro hook tape on the metal plate.

With the combination of Velcro loop and Velcro hook tape plus the D-Ring Velcro
strap.. my flashlight / radio is pretty much vibration free. I suppose if my
D-Ring Velcro strap is long enough.. I could probably secure a water bottle on
my handlebar as well. The connection is that good.

NOTE: In case the Cateye quick release bracket fails -- because it is made of
plastic and is only anchored with one screw.. I recommend that your electronic
device have a lanyard, and D-ring clip the string to a brake cable.. so the
device won't fall onto ground if the bracket ever fails.

As for flashlights.. Princeton Tec - Tec-40 has received very good reviews.

Most stubby 4-AA flashlights will work fine. The nearly 2" reflector lens in
these models are much better than the Micro 500II, the Cateye HL1500, and any
other bicycle lights out there in the price range.

UPDATE: (9/27/2004) I now use a Aztec 4aa stubby flashlight with an EverLed
bulb with this DIY handlebar bracket.. I am a happy camper!

Choices of Flashlights and their applications can be found at..
www.flashlightreviews.com

FOOTNOTE: My 2.5" x 5" metal plate as describe above is actually curved to
conform to the natural curb of a standard round barrel flashlight..By having
the plate slightly curved.. it cradles the electronic device that much better.

If you want a cheap commercial flashlight handlebar mount and many other hard
to find parts.. browse through www.bikepartsusa.com. and punch in key word
"flashlight". The end result will be Wald #40 flashlight handlebar mount for
$2.00.

Pic #1: bottom view: base plate / bracket with cateye spacer attached.
Pic #2: top view: series of adhesive velcro tape and velcro D ring strap.
Pic #3: side view: with Aztec 4AA flashlight with Everled PR base bulb.. amazing light.. approximately 40 lumens -- maybe more.


Much obliged.
Nick