Reader Ross wrote to us with an enlightening hack. In his own words he states:
I came up with this hack because I entered a 24-hour mountain bike race and didn't have a high powered headlight/backup headlight system.
He labels his hack: Cheap and easy 340 lumen bicycle light and mounting bracket. I would officially change it to:
BADASS Cheap and easy 340 lumen bicycle light and mounting bracket
The pictures and instructions are all Ross. Makes me want to go out a buy a Dremel. Thanks Ross!
-Old handlebar stem
-(4) medium hose clamps
-(2) high-power LED flashlights
-Dremel with cutting wheel
-(optional) Pipe cutter
Note: I found two 170 lumen LED flashlights on sale at Kmart, but you can use any aluminum-body flashlights you have on hand or see for sale cheap. Use aluminum-body flashlights for better heat dissipation (the mount works as a heat sink).
1. Remove and discard the stem binder bolt and cinch (the triangular/cylindrical piece that holds the stem against the inside of the fork tube)
2. With a pipe cutter or Dremel with cutting wheel, cut off the pointy part of the stem and file off any rough edges. Wouldn't want to impale somebody with that!
Caution: You MUST wear safety glasses when cutting metal. Don't force the cutting wheel -- let it do the work on its own. Aim the sparks away from your eyes. Cool the stem with water as it gets hot.
3. Using the Dremel with cutting wheel, cut eight 1/2" slots in the stem tube. Cut four slots (upper and lower slots) on each side of the stem tube. Cool the stem with water as it gets hot.
4. Unscrew a hose clamp. Insert the clamp tip into a lower slot in the stem, then out through an upper slot. Repeat for the remaining three clamps.
5. Secure the flashlights to the modified stem using the clamps.
6. Attach the assembly to your handlebars. I prefer to hang the assembly below my handlebars.
7. Adjust beam angle, as needed.