Interested in a DIY LED running light kit?

[ArthurKnowles]

I purchase 100 55,000 mcd LEDs for about $15 delivered. I thought I'd make a set of front running lights for my RT & LT. Before I do, I thought I'd check and see if there is any interest in others to do the same. If so I will document and write up a brief how-to article and post it on my web server.

[LTExfisher]

I for one appreciate any and all instructions posted on this site ! ! ! :bmw:
Thanks for DO'IN it !

Sam

[myk_edwards]

Go for it, and I'd like to bet Ari is the first one to install them:) after you.

[hip001]

I may be interested!
I need a good reason to blow the dust off of mine!

[Ron_Kendall]

I for one appreciate any and all instructions posted on this site ! ! ! :bmw:
Thanks for DO'IN it !

SamAnd I will second that.

[ArthurKnowles]

Ok, I'll document what I do and create a web page with manufacturer links for materials. It'll give me a chance to use my new camera.

I'm looking to build two basic shapes. A rectangular one that can be mounted with exterior mounting tape and a round one that can be mounted similar to motolights to improve visability.

I'll post a link to the web page when I get it done.

[Steve_R]

Rider West has kits already available for those that aren't much of a tinkerer. Rider West (http://www.riderwest.com/)

[ArthurKnowles]

Actually, RiderWest does not have a kit for what I was proposing. Hyperlights does have a solution however, for those that prefer the prebuilt choice.

[Steve_R]

Sorry Arthur, I guess I misunderstood what you're up to. Pictures when you're done will be appreciated. :)

[ArthurKnowles]

No problem Steve, I reread my orignal post and noticed I wasn't quite specific enough. Here's a link to a web page with my current status. I'm stopping for the night to let the glue dry and tomorrow I will get to soldering the resisters and purchasing the plastic I need to make a mold for the epoxy base.

http://www.nt-guru.com//Motorcycle/FronLEDDrivingLights.htm

[ArthurKnowles]

Well bad news, the molds leaked. So I need to build a new set.

I suspect I should have used the silicon rubber seal instead of the wax seal. The epoxy has an exothermic reaction and I think it melted some of the wax sealing it as well as warping the mold and promoting leaks.

So, looks like I'll get a chance to rebuild it a bit cleaner this time around.

[wacolt]

I'm looking to build two basic shapes. A rectangular one that can be mounted with exterior mounting tape and a round one that can be mounted similar to motolights to improve visability.

I'll post a link to the web page when I get it done.

How about a star in a circle? (Just kidding!)

I admire those with imagination! Thank you for sharing your process with us.

[ArthurKnowles]

How about a star in a circle? (Just kidding!)


I could do that! Might get nailed to a cross for my troubles though. :)

Truthfully, one of the nice things about DIY is you can be creative and make different shapes or outlines. And of course, there is always the smiley face to use too. :)

[Jabrown]

I have been thinking about modifying the front turn signal housings to kind of replicate the audi R8's funky headlights.

[Hollywood]

I could do that! Might get nailed to a cross for my troubles though. :)

Truthfully, one of the nice things about DIY is you can be creative and make different shapes or outlines. And of course, there is always the smiley face to use too. :)
Not sure how much you are spending on the parts plus what ever you value your time at, but I found these on ebay: http://cgi.ebay.com/ebaymotors/Super-Bright-Blue-LED-Fog-Lights-Foglights-Driving-Lamp_W0QQcmdZViewItemQQcategoryZ36476QQihZ002QQitemZ120277545081QQrdZ1QQsspagenameZWDVW
They are going for $12.99.

[NascaLT]

The LED's from LED Options International (as noted on the eBay link in Hollywood's post) sure look like they'd do the trick, especially for the price. But be wary of the "Ultra Blue" color; that's a LE color in many states and border on what is legal and what isn't. Pick another color, probably save you a citation.

[ArthurKnowles]

I spent about $30 on LEDs. The rest is free (for me) as I have all the materials. But I may look into those as well. Different color though. I'm actually putting 24 LEDs in to each light. They are very bright. But ...

Pictures of my first molding disater are now online. One mold leaked. Both molds got overheated from the exothermic reaction fo the epoxy. And on the good one (more or less) wouldn't you know it ... one LED no longer works. I suspect the epoxy had something to do with that as it cured.

So, I have to build a new set. So, what did I learn?

1) Don't use so much epoxy. Only need enough to waterproof the electronics and provide a stable mounting point.

2) Make a better mold. SOmething that can take a bit of heat. Or use a different type of epoxy with less exothermic reaction. Or just less epoxy.

[Hollywood]

I spent about $30 on LEDs. The rest is free (for me) as I have all the materials. But I may look into those as well. Different color though. I'm actually putting 24 LEDs in to each light. They are very bright. But ...

Pictures of my first molding disater are now online. One mold leaked. Both molds got overheated from the exothermic reaction fo the epoxy. And on the good one (more or less) wouldn't you know it ... one LED no longer works. I suspect the epoxy had something to do with that as it cured.

So, I have to build a new set. So, what did I learn?

1) Don't use so much epoxy. Only need enough to waterproof the electronics and provide a stable mounting point.

2) Make a better mold. SOmething that can take a bit of heat. Or use a different type of epoxy with less exothermic reaction. Or just less epoxy.
Take a look at some of those LED and HID lights on ebay. I have bought stuff from some of those guys out of Hong Kong and they ship fast.
They got some cool stuff if you look at there "other listed items".
Found some nice LED strip lights that you can bend in any shape..... IDEAS!

[eaglemike]

Arthur,

If you can get some mold release, and/or think an aluminum mold would be handy, maybe I can help. Maybe line the aluminum mold with plastic notebook cover, tacked in place with contact cement?

all the best,

Mike

[ArthurKnowles]

I actually have some PVA mold release. Just didn't think I really needed it for a one-off project with the plastic. Usually plastic peels right off. It did this time too, but needed a bit of heat to pull it off.

I was thinking I'd do it the easy way with a bit of play-dough. It set's hard, but has a tendency to shrink a bit. So, I'll have to make a box to prevent compression on the mold. Basically, I'll put a completed LED module in the play-dough and lay a solid box on top of it so I have a mold that will hold the completed unit in place and still allow me to pour the expoxy. Just a 1/4" this time. And before I use it, I'll spray it full of PVA and put a couple of dental floss lines under it to make it easier to remove.

I also looked at a coupld o LED items on eBay, but the shipping charges still make them more expensive. BEside, I guess I really just want to do it myself anyway. :)

[jayjacobson]

Great fabrication, Arthur! I only dream of having the time to build....one day....

[eaglemike]

I have a little spare aluminum around. I was thinking (always a challenge) I could set up a pocketing routine on one of the mills and whiz out a mold for you. Also watch how you do it and maybe do it for myself, too.

all the best,

Mike

[ArthurKnowles]

Mike,

That would be interesting. The hardest part (right now anyway) is creating the faceplate to hold the LEDs. I have to drill very slowly with very little pressure to prevent breaking the plexiglas or elnogating the holes when it gets snatched by the drill threads.

I bought some Crayola air-dry clay today for a new mold. I'm going to create new faceplates and build a clay mold over the weekend. For at least one of these lights. I don't think I have enough for two as I had a few LEDs pop after giving it a bit too much voltage. I have new ones on the way though.

If you want to see how/what I do, feel free to PM me and we can set up a time this weekend. I'm not too far away from SD proper (about 45 minutes to an hour depending on where you are) in Fallbrook (between Escondido and Temecula off I 15).

As an FYI, If I were using aluminum for the faceplate (and I've thought about buying some more - I ran out of what I had) I think I'd put one or more mounting tabs right on the faceplate so I could bend it 90 degrees and put a bolt through it. Shoot, now you've got me thingking I should head out to the hobby store and buy some.

Art

[Hollywood]

Mike,

That would be interesting. The hardest part (right now anyway) is creating the faceplate to hold the LEDs. I have to drill very slowly with very little pressure to prevent breaking the plexiglas or elnogating the holes when it gets snatched by the drill threads.

I bought some Crayola air-dry clay today for a new mold. I'm going to create new faceplates and build a clay mold over the weekend. For at least one of these lights. I don't think I have enough for two as I had a few LEDs pop after giving it a bit too much voltage. I have new ones on the way though.

If you want to see how/what I do, feel free to PM me and we can set up a time this weekend. I'm not too far away from SD proper (about 45 minutes to an hour depending on where you are) in Fallbrook (between Escondido and Temecula off I 15).

As an FYI, If I were using aluminum for the faceplate (and I've thought about buying some more - I ran out of what I had) I think I'd put one or more mounting tabs right on the faceplate so I could bend it 90 degrees and put a bolt through it. Shoot, now you've got me thingking I should head out to the hobby store and buy some.

Art
I'm telling ya, check out those ebay LED HID lights. Heck, for $9 - $24 you can get whatever you want, then spend the time fabricating the mounting system for all your new lights!
http://cgi.ebay.com/ebaymotors/Supe...sspagenameZWDVW

[ArthurKnowles]

[QUOTE=Hollywood]I'm telling ya, check out those ebay LED HID lights./QUOTE]

I already did. I found a couple of potential possibilities, but I can do better in the lighting arena. Some of the lights I liked were jsut too expensive to ship form China. At the best price, they were $20 but only included 12 LEDs per light.