Here is my Electra Townie Balloon 3 (more info on it and it's carp slaying usage in this thread:
http://www.bikeforums.net//showthread.php?t=444390)
The Electra LED Bullet Headlight:[IMG]file:///C:/DOCUME%7E1/1/LOCALS%7E1/Temp/moz-screenshot.png[/IMG]
http://www.amazon.com/Electra-Bullet.../dp/B000NWP2D0 is a sweet looking retro light, but the stock LED has the candle power of, well, one candle. It's unsafe and useless as a light but it looks really cool. (Note: There are many bullet headlights on the market, this will work with any of them, I would guess).
Enter Cree, problem solved! I used a "Cree R2-WC 250-Lumen 5-Mode Memory Drop-in LED Module for Flashlights (3.6V~8.4V)" SKU 14442 from DealExtreme:
http://www.dealextreme.com/details.dx/sku.14442), some of these battery holders:
http://www.batteryspace.com/index.as...OD&ProdID=2320 and this set of 3.6v RCR123A batteries and charger:
http://www.batteryspace.com/index.as...OD&ProdID=1387
The Electra switch is easy to use as a momentary switch to select modes with no modification. You just flip it back and forth to cycle modes, then click it all the way on once you find your desired setting.
To mount it I sanded the (plastic) reflector plate down until the drop-in fit perfectly through the hole. Three daisy chained tie wraps hold it in place to center and aim it. Silicone II is liberally ****ered around the tie wraps and module to hold it firmly to the reflector.
I used the drop-in's aluminum reflector module in this setup to provide more of a heat sink. The brass heat sink of the circuit/LED is too hot to use on it's own mounted to the plastic reflector. As an added bonus, upgrades will be as easy as unscrewing and desoldering the old one and popping a new one in.
The battery holder assembly is made and mounted with 3M Scotch Dual Lock (über velcro), a velcro retention strap, super glue and a bit of extra double sided tape to fit the curve of the light chassis.
With 2ea. 3.6v RCR123A batteries in series at 7.2v (8.4v peak) it runs on "high" for 2 hours of nice bright light, then about a half hour of OK light equivalent to medium on a full charge. I have another battery holder built for the option of adding two more cells (in series parallel, still 7.2v) for longer runtimes. I avoided putting it in right away because the LED's heat sink (the brass ring you see) gets very hot and would be very close to the batteries. I would rarely go for a ride longer than 2 hours at night but if so it's fast and easy to change batteries, even by feel in the dark.
I didn't add a protection circuit to this but I may do so if I decide to add a charging jack. Protected cells would work nicely as well, I considered these:
http://www.batteryjunction.com/uf16340.html and may upgrade to them in the future.
There you go! A light can look retro cool and still be functional. I'm VERY pleased with the performance of just one Cree R2, the hotspot and ring are clearly visible on the road even directly under streetlights. It lights up the local canal path very well. On my first test ride I stunned and blinded an opossum - it didn't move until I was about 2 feet away from it, then I saw it's eyes reflecting moonlight in the bushes as I passed. Electra LED Bullet Headlight - Now with 'possum stunning action!
I hope those looking for a retro yet functional bicycle light find this post illuminating.
PR