DIY Bicycle Light and Mounting Bracket
August 29, 2024
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!
DIY Bicycle Light and Mounting Bracket
Parts:
- Old handlebar stem
- Medium hose clamps (4)
- High-power LED flashlights (2)
Tools:
- Dremel with cutting wheel
- Metal file
- Pipe cutter (optional)
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).
Steps:
- Remove and discard the stem binder bolt and cinch (the triangular/cylindrical piece that holds the stem against the inside of the fork tube)
- 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.
- 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.
- 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.
- Secure the flashlights to the modified stem using the clamps.
- Attach the assembly to your handlebars. I prefer to hang the assembly below my handlebars.
- Adjust beam angle, as needed.
