Hello BLF,
Always wanted to improve my visibility to others in traffic when motorcycling (main goal) and also wanted to improve nighttime visibility ahead of me maybe 5-10 meters.
Brand name spotlights were too expensive for my budget and cheap Chinese lights just weren’t good enough. So I decided to build them.
How hard can it be?
This build is a follow-up from this topic (Help me choose some components), many thanks to all that helped with advice.
The main components used are:
- Cree XHP50.2 K2 3C Neutral White 5000K
- Aluminum bar 50mm x 150mm
- O Rings (different sizes)
- Mounting brackets x4
- Wire - different sizes
- XT60 connectors (male - female)
- CC CV modules x2
- Round glass x2
- 5 degree led lenses x2
- Stainless steel bolts - different sizes
- Automotive relay 12V
- Fuse + holder
- Switch 12V
1. Aluminum bar
2. Let’s make something out of this piece
3. Boring the hole for CC CV module
4. Hole bored, PVC pipe will be inserted to insulate the module from accidental shorts
5. Other side - Boring the hole for led and lens
6. Body done!
7. Making the bottom lid
8. O ring fitted
9. Getting there, I also added additional PVC insulation to prevent accidental shorts
10. Six M2.5 stainless steel bolts to secure the lid
11. Top lid
12. Getting there.
13. Added six M2.5 bolts to secure the top lid.
14. Cooling fins
15. Done!
16. Test fitting the light on the motorcycle, looking good.
17. Adjusting the current, 1.5 Amps should be enough. If not I can always readjust it later.
18. Prepared for the paint job.
19. All done, spotlights are ready for the final assembling
20. Assembled!
21. Brackets mounted
22. All the wiring is done, and spotlights are bolted to the forks
23. They are alive!
24. Front view
That is it, hope you like my project.
If you have any questions, I’ll be glad to answer them.
Cheers 
