It looks like youâve thought this through pretty thoroughly, and IMNERHO made some pretty good decisions.
I tested a standard XM-L based P60 against the stock headlights on a Toyota pickup, and the P60 blew the headlights away, by a lot. 3A may be more than you need. If you use one of the drivers & wire the LEDs in Series (set your output voltage to 5 or 6) youâd only need the one.
That first optic you linked is 25°, and its holder has to be glued down. Maybe a bad choice for the holder, but I think, given that scooters arenât able to go âthatâ fast, the 25° beam will be hard to outrun. Youâre correct that the 2.5mm holes on the drawing are for mounting screws, as alpg88 illustrated. Your cheapo optics also come with glue-in holders. The screw-hole ones would be the easiest on you, if only because you wonât have to glue them down, even though youâll have to be careful to get a âstarâ (LED heatsink) which fits it properly.
Since youâre using holders, you could, say, put the 25° optic on the âtraffic sideâ and get a 10° for the âshoulder sideâ to get a better look at approaching danger. With holders, you get to experiment with them easily. The optics just pop in and out. And the existing headlight will take care of the close-in things.
The copper bar is going to be your Heat Sink, of course, so youâd want it at least 25mm wide (that optic is 21.3) and 4+mm thick to get the heat away. A modern PC video card comes with a nice round Al heat sink you might use⌠See if your local computer repair store will let you raid their trash for the cheapest ones. At 3A, youâre going to need all the help you can get.
If your bar is wide enough, once you get everything working you could âpotâ the optic holder in epoxy or silicone caulk. That would be more decorative than useful, thoughâŚ
Other than for that driver, you wonât really need much for waterproofing; but you will need to put a layer of Thermal Compound between the LEDâs âstarâ and your copper bar, to both transfer heat and prevent (or at least delay) the inevitable bi-metal electrolysis that will occur there. Potting the optic will help here too, but all youâd really need would be a thin bead where the âstarâ and the bar come together, and something to seal the solder joints on the âstarâ.
Iâm looking forward to following this thread! Nice ideas!
Dim