A new turn signal/brake light project

The total cost for my system would be between $160 and 200. Some of the components were given to me for free, such as the brake light housing which is actually an old yamaha turn signal, and the brake lever. Cost of the brake lever and turn signal depends on where you find them, one of my buddies found the lever at a moped/scooter junkyard, and another buddy of mine found the turn signal at a flea market. The power distributor was also given to me, but the most I've seen them go for is about $30 on ebay. I added that into the estimated cost. Granted I don't have turn signals, and that would make the system a bit more expensive, but probably still a lot less than $450 or so.
 
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I wanted to build the whole thing from scratch. Here are some pictures of it. 140409_0001.jpg140409_0002.jpg140409_0003.jpg140409_0004.jpg140409_0005.jpg
 
Ok well, like I said, just trying to share ideas. I usually only think building from scratch is a good idea if it's cheaper than buying pre-made, or if you can get individual components of better quality than pre-made. You said you were worried about some of the components handling a beating, just saying, my system has been put together since last summer, and I only had trouble with two components. One was the first toggle switch I was using, couldn't keep a good connection due to vibrations. Replaced it with an automotive quality switch, no problems since. The other was the first bottle genny, that's another story but suffice to say it's replacement is holding up just fine. It looks like you've done a good job, but unless you're planning to market this setup and the prototype is a test bed, you've gone to some unnecessary trouble and spent a good deal more than you needed to. If you are planning to market that setup, good luck. Very few people here are going to buy a $400 lighting system for a $250 homemade moped. You're better off marketing to hipsters. Not trying to be rude, just telling you the truth. If you can cut the price in half, you might get a few more customers. But considering the fact that a guy like me can build a lighting system without much prior knowledge of circuitry, I'd say the chances are slim. It took me some time to figure everything out, but I did it. I started with two r/c car batteries wired in series and an incandescent bulb for the brake light. Switched those out for an led and an sla battery. It worked better, but I got tired of wall-charging every so many days and decided to build the charging system. My point is, imho, most mab enthusiast will probably buy pre-made lights that run on batteries, such as the cree brand that's becoming ever more popular, or if they want to go all out like I did, they'll do their research, scrounge whatever parts they can, and buy the rest pre-made. There is a certain percentage of people in this market who will buy expensive items, collectors, show-piece quality builders and those who use their money to build fleets of fancy toys. But that's not the majority here. Of course, if you're building it for yourself, then I'm sure you've got your reasons for wanting to do it this way. Either way, I don't mean to offend. Just trying to share ideas and insight.
 
The system I made is not like anything that is available on the market, or elsewhere. It is too complicated. The main advantage to it is that it doesn't need a separate brake light. It has 2 rear lights...not 3. When I ride it, I know that no one has a turn signal system like mine. If someone wanted to buy my system, I would have to warranty it, but why would I start a new business venture if I am going to retire next year?? I'm past the days of scrimping and saving. $200, $300, $500, or $1000 for a turn signal system...I don't care. And I don't care if some one doesn't want to spend $400 for a turn signal system because I understand.
 
140411_0001.jpgHere's a copy of the shimano dynamo 6v 3watt hub circuit. This is a better charging device than the cheap bottle generators that wear your tires out when they were used in the 1950's. This circuit is for the serious riders that need a solid source of power for their bikes.
 
I get such a good feeling when I see a MB with turn signals. The automobile drivers do pay attention to them too. Does yours have brake lights, or do both flash together? I guess its time to do an update on my project. The dynamo generator schematic I posted needed a bridge rectifier connected directly to the 6V dynamo hub. Then the 6.2V zener, then the 470 uf capacitor.. I'm close to having the PC board finalized by futurelec. The PC relays passed the shock test. I gave them a real good vibration and shock test. No failure for the whole year.
 
No brake light yet but in th he pipe line, not good with wires and stuff but it seems to work, any idea how to make lights flash, at the moment it just a push button mechanism
 
No brake light yet but in th he pipe line, not good with wires and stuff but it seems to work, any idea how to make lights flash, at the moment it just a push button mechanism

Do you have a 6v or 12v battery? You will need a flasher circuit. At this point, it will start to get technical. Look for a automobile schematic for the wiring diagram. You will have to go with a separate brake light ,and separate turn signal to keep it simple. With the brake light, you will need a brake light switch that connects to the rear brake cable.
 
I used a $5 turn signal flasher from autozone for my turn signals. no need for a complicated 555 timer circuit
 
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