Now that I have replaced the strobe that I could not get to work with a beehive amber LED, I've turned my attention to the front light. I got a 3W Luxeon emitter (100 degree spread) from
http://www.superbrightleds.com/MR16_specs.htm . However, when I put it in the Optronics housing it was a bit too long. I went to Home Depot and tried to fit it into every plumbing device I encountered, including some shower heads. Finally, I remembered reading about a home-built light using a Mag-lite as a housing. This is a total theft of idea, and it doesn't come up when I Google on "Mag-lite" + "bike light". My apologies to the brilliant author of the idea. (
http://krabach.info/bike_light/bike_light.htm also uses a Mag-lite, but not quite so elegently.) Basically you screw off the head of the Mag-lite, then take the lens cover off and discard the reflector & bulb, save the lens. Pull the MR16 base out of the Optronics housing, insert the MR16 bulb into the base, then drop the bulb & base thru the front of the Mag-light, put the lens back on and replace the lens bezel. Now you take the handle that you removed from the Maglite head and hacksaw off the excess front end (yup, you are going to waste the switch and nice threaded end. For my light the tail end about 1/4 inch short of the knurled grip was about right. Slide the tail end into the head. I first tried to slide a strip of old inner tube over the joint to hold it together but couldn't, however the struggle gave me a good friction fit which I sealed with silicon tape. Next I took one of the many quick bar clamps I have lying around, messiness is usually rewarded, filed off the dog ears that were meant to hold a light base, ran zip ties thru and then snugged them up of the amputated handle. Hopefully, attached photos will help you see what is done. The resulting light is not light, 9 oz, but pretty neat looking on my bike.