by GMP » Wed May 27, 2015 7:50 pm
My helmet light has four LED emitters and runs on an eight cell pack, of which I have two. I had it on for 2 hrs on high and it was still going strong, spec is four hrs. run time. I should measure the current draw and calculate the actual power and run time based on the battery capacity. I found larger packs (with larger cells) direct from China with the same connectors for $18.50.
The helmet/bicycle lights are different than the automotive grade lights in that they only run on 8.4V and have a simple driver. The larger lights like the 10W emitters and combo bars use a broad input voltage range driver and have much greater mass in the heat sinking. They are also tougher and heavier and I suspect more vibration tolerant.
As far as my headlight goes, I did not make it specifically for night riding, but as a replacement if I needed something for an enduro or occasional ride where one is required. For pure output you can do a lot better in the space occupied by the number plate with a variety of LED arrays of different shapes and sizes and some basic bracket work, keeping power within the range of the stator of course. I chose to use a small bar because it will be shared between Steve Beane and myself for night shifts in the 24hr, and will mount to our Flexbars, and will not require removal of any OEM headlight or number plate. Rapid R&R with no interference to brake line was also a design goal. What also is required is a rectifier of adequate rating for the existing AC light ckt., and the DC output for the light MUST be isolated from the frame ground. No big deal as the lights case is isolated from its DC gnd. A regulator is not needed because of the 9-48v input range of most of the lights, and the small AC regulator in the system does a good job of keeping the input low enough so the output DC does not exceed 18v on my bike at least. You can add some filter caps to smooth some flicker at idle but it really not necessary.
From my limited experience I would say get your helmet light setup first, you need that for sure. Then depending on terrain and speed look into a higher power array on the bike.
Here is a pic of my simple headlight. Two cheap 10W clones of the original VisionX Solstice. Onboard rectifier. My harness is mostly cut down to minimal but I added a waterproof coaxial power connector for secure and rapid R&R. No switch its just on all the time, simple. Been beaten and shaken up pretty good and seems solid so far.
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Glenn
'13 Beta 300RR Racing