diy bike light

Don’t be afraid, I’ve been using these striped TIR optics for long. IMHO no better way to light up road (including corners) without blinding people around. Just pay attention to not to buy the cheapest $1 easily available. I recommend especially Carclo (gained 29% of light output when I switched from noname optics to Carclo).
If you want more budget option, you can trust Yajiamei optics - huge variety, easy accessible from Ali but usually lenghty delivery.
For Convoy S2+ you need 20mm diameter optics, you may also choose the sides of beam pattern ratio to your liking: 30x60, 15x45, 10x45 etc.
Just pay attention to the size of your led. There are ones dedicated for 3535 pattern, some for 5050.

If you need a hand in choosing - just PM me.

WLE - three months??

1stein - thank you for the information. I have had very little experience with optics other than reflectors and will pm you if I need more info. Thanks for the link to yajimei optics as I was unaware of them.

Any suggestions for a carlco eliptical (or other suitable biking optic) for a p60 setup? One of my p60’s has an xml led as I recall.

John.

yes 3 months, tell me when you are satisfied with the project…
also count this week of asking questions and designing the thing

i find the $30 ones entirely good enough

wle

Lightbringer - thanks. Will look into this.

John.

No worries.

You might need a spacer to make up for and difference in height between reflector vs lens, but I have no idea how much that’d be.

I saw this new lamp that looks like it is interesting for headlamp or bicycle: https://www.aliexpress.com/item/4000118308868.html?spm=2114.12010611.8148356.1.391b5c6f6dX7Z4

Lightbringer - I got thinking about the p60 setup and realised that I pack aluminium foil between the reflector and the body of the light to transfer heat. Not sure how that would workout with an optic instead of the reflector. I am running a fairly hot setup. Have you had any experience with that?

clientequator - looks like a decent light and the specs don’t seem to be too exaggerated. The problem I see (if the photo is accurate) is that it will likely give a round beam and thus not be the best for staying out of other road user’s eyes. I don’t know if an optic could be used to modify the beam.

Thank you,

John.

Drop-ins are not the most thermally conductive setups. I’d definitely go easy, or go without. Otherwise it’d cook.

I always wondered, with big honkin’ handlebars and frames, why no one ever came out with a big thermally-conductive bracket for mounting a light. If anything, they’re rubber-lined and thermally insulating.