[DIY] 3x XM-L U3 bicycle light project

Pricey yes, but I would guess price to be higher when I first read that instruction. Programming that surely can take some time to handle. I’ll give you a call if I get stuck at somepoint.
Threemode sounds like good setup.

I’ll make extra pill that I screw first in body. While assembling the light I screw that extra pill to bottom of M30 thread. Then I add heatsink shim ( ordered one of these also ) to driver with adhesive and add some thermal compound on otherside. After that I screw pill to body and drivers heatsink should thicken to extra pill and transfer heat to body. That is what I planned now :).

Edit. BTW. What kind of clicky do you use with your lights? I was planning lockable clicky, but with this b3Flex driver I should use non-lockable. Do you happen to have some good suggestion?

Very nice job on the machining. I look forward to seeing the final result.

you need some kind of momentary (normally open) switch. for my bar light I have both an IP68 switch with a stat LED (for voltage warnings) and a remote switch I made with an old microswitch I had laying around. I :heart_eyes: remote switches. I think Judco also do wired momentary switches, which would make a remote switch a lot easier.

If you want only 1 cable gland going into the back of the light (you could always mount a 3mm LED on the body as a stat LED) you can use a 4 core wire and splice off the wires to the battery and to the remote.

Oh, and it will be worth thinking about a 4S2P battery, as the overhead on the b3flex will cause the light to fall out of regulation (dim) about 2/3 to 3/4 of the way through the battery discharge if you use a 3S2P battery. That’s pretty much the only disadvantage to using a buck driver for a triple XM-L.

Thanks!

Yea, I thinked also that 4 wire cable would be best option. Also like you said I thinked that i should get extra pair of batteries to get 4s2p setup.
I’ll start hunting right switch now. Thanks again for help :slight_smile:

Edit. And thank you Chicago X!

no worries! Looking forward to the finished light :slight_smile:

Still eagerly waiting for that driver.
But in the meantime I did got parts for switch and would like to share some pics and info about that.

Here’s parts that I bought
(ABS-10 host , 59P switch , 3mm led , PU5x0,25 cable , DA40 grommet and some velcro strap )

After making button hole little bigger and holes for starp ( also did put some silicone inside, so it’s waterproof ) - here’s finished switch.

neat remote, I like how you put the stat led next to the switch. It’s always good to see different approaches to remotes. I’m going to try and incorporate my next one into the brake lever clamp to reduce the reach, not quite sure how yet.

Thanks!

It’s fun to watch work of different people. All of us think individually, so you get good ideas from others :slight_smile:

Mounting to brake lever is good idea. Would love see how you make it.

Can I just say, this is an awesome project. Keep us updated.

I’ll let you know as soon as I figure it out myself :slight_smile:

Thank you gords1001! I’m liking this project also. :slight_smile:

matthemuppet: That would be awesome!

Okay, so I did get that awesome taskled b3flex driver on friday. Was very psyched to continue with this project.
I measured correct places for leds on pill and put those together with adhesive

Then on otherside of pill I soldered led wires to driver

So far everything was perfect. Then I soldered all other wires to driver and fastened it to body. Tested it with 4S1P battery pack. IT SHINES!!
Light started up nicely. After little configuration for driver everyting was setup for this light. When I had been playing with light for a while i noticed that it does not go OFF correctly, two out off three leds had some “moonlight” dim going on while light should have been off. So there had to be same leak to body that this could happen. At this point I should just have let it be like that, since it was pretty minor. BUT I want to make everything work perfectly, so I opened light again. I did found out that while I fastened the pill there was wires that contacted the body. I should have done pill little differently, but I did not want to make that again. So I started to make little modifications to … hmm … everything. After many bad decisions, too many hours, too little food and one angry wife later this is what happened

So I as you can imagine the light won’t start up again. I spoiled driver. Luckily driver was only one that got destroyed in this mess. Basicly everything gone to hell with this project in past two days.

Well… there is really nothing more to do now than clean up, learn from mistakes and order new driver. Atleast now I know what I should do and what I should not do (If you want to try find some good things about this). :~
Not my weekend.

BUUT tomorrow is new years eve and it’s time to relax. I wish all fellow members a very good new year!

I love it! You need a trash can right next to the table. I have a trash can about 15’ away, so I can do basketball shots into it, with my mistakes!

It really is a beautiful build and I know you will come back to show it off when it's done. It looks like you are doing well and as you say, learn from your mistakes, so it should be ab awesome light!

Thanks OL!

Trash can sure would be handy and throwing basketball shots to it would also cheer mind up :slight_smile:

Bugger. It comes back to the old saying that if something can go wrong it will. Tomorrow is always a new day that brings a clear head and with any luck a happier wife. To you as well have a happy new year and looking forward to the next chapter in this amazing lght. Cheers.

Great machining skills! How did you polish the parts?

Thanks! That saying seems to be very true. It’s a new day now with clear head and new plans for how to implant that driver ( happy wife also :).

Thanks!
I used 800&2000 sand papers. After that I used two types of waxes with leather to get finishing polish.
Parts that I made in lathe - I also polished in lathe.

I use 400 grit sand paper on a lathe, diamond pastes and soft cloth to get mirror finish.

Really nice work. George at Taskled makes very good drivers but it takes a lot of patience to cycle through 13 different programming modes. Nice that you can set low voltage warnings at different levels using different battery setups. Thank you for posting set backs as well as successes. That’s the way modding can be with a first time build. Looking forward to your results.

Thanks! Yea, those are really nice drivers. It makes light much much more usable. Set backs are my way of learning things :).

Great work man! That truly is mirror finish!