$5 Home Depot headlight revisited

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Brake light switch

More of the same with internal shots- if you are clever enought to build a motorized bicycle, this should offer no challenge
 

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brake light switch

As seen in the prior transmission, the two brass screw heads go inside the tube to provide outside contacts- the brass washer (held LOOSELY by a small flat head screw) finishes the connection when the spring pushes it against the round heads. Now the set-up on the caliper is simple- the switch mounts to a bent piece of steel that is latched under the adjustment set of the cable for the brake. a short legnth of stainless steel necklas chain is attatched to the end of the orange fiberglass rod ans also to a tiny slipring- said slip ring loops onto the excess brake cable on the caliper. When the brake is relaxed, it pulls the rod down and interrupts the connection. When the brake is applied, it releases the rod and completes the connection, thus activating the light.
The photo shows the first such unith I built- different hookups, but same principle
 

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Brake lever with switch

Great job Sarge.This way it keeps extra wire off the handle bars. I think I've shown you what I use for this in a prior post. It involves more wire going up the bars, but it's clean enough looking and easy to install. The price seems to have gone up on them since last time but it's still cheap enough.
http://www.ebay.com/itm/Right-Hand-...ultDomain_0&hash=item51a70d192a#ht_937wt_1168
Big Red.
 
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Yea, that will work- an extra wire going up the handlebars is a minor issue compared to the labor that my switch involves... but sometimes those things can't be had, so I came up with this alternative
Truth be told, I prefer the handle switch- easier to install and already built. But if you can't get it, or can't afford it, or just want to do something different... there it is.
Next up will be battery compartments and a look at mounting hardware.
PS- I've figured out how to put a brake switch on a coaster system. I think it's patentable...
 
Thats always been my biggest problems, Trying to figure out where to put a battery box. On my personal bike I installed the ammo boxes. One side for the battery, flasher unit and such. one side for tools, rags, ect. On most bikes there's not a lot of room left over for a box.
Ya gotta tell me how ya worked out a brake light on a coaster brake bike. You mentioned it a while back. I wasn't gonna ask cause I'm sure you don't want everyone running to the patant office. But I'm REAL curious about it.
Also, I've got a couple people wondering when the next run of the Howard mounts is comming out.Soon I hope. You have my email so you can contact me through that if ya want.
Hope to hear from ya soon.
Big Red.
 
I have been running a 'Panama Jack' with four 'AA' rechargables for the past few months with no ill effect or substandard performance. This is with the white wire/hotbox combination charging the batteries. Four penlights? I'm sure you can find room for that. Radio Trash even sells battery boxes for them.
 
I've seen your battery setup before. Guess I just forgot. Four AA rechargables could go anywhere.
Big Red.
 
Hotbox Housing

... And further down the rabbit hole we go-
Here are four images of the main body finished out plus one of the whole operation on the bike product- the electronics are not inside at this time. This is where the bridge rectifier (hotbox) will go
 

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More hotbox

Here are four more shots of the mount on the bike- those screws holding the access plate will be replaced with round heads as soon as I buy them. I have a fellow in town who knows his way around plastics. He has explained to me what is involved in making a mold for injection, and I have come to realise that I have the tools and skills to do it while he has the savy to make the injector- between the two of us we might start production on a variety of bike mounted housings for a multitude of uses, mostly electronics and panniers and such... but now wouldn't it be cool to find out the stuff they make plastic gas carriers out of? We could roto-mold gas tanks!!!
Personal note- Thursday I go to Seattle to get several arteries in my heart stented- it is called 'angioplasty' and it is much less effort and risk than a coronary arterial bypass with graft ('Cabbage' is the usual term). Should all go well, I will be back to work monday the 20th. If not... might be a bit longer...
 
Oops!

Forgot the silly pictures!!!
BTW- these are made out of genuine GOPHER WOOD! Yea, that's right- what Noah used to build the Ark! First person to tell me what that means gets a FREE hotbox for a China Trollop engine, just tell me the seat post diameter... or whatever diameter you wish to mount it on! Reply on this thread only!
 

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