Three pieces cut from 1" square aluminum tubing. (Make a dual LED version by just omitting the middle piece and cutting the main body shorter).
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Scoring the pieces for better bonding with JB Weld
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JB Welded and Clamped
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Initial fitting together, followed by a lot of filing and Dremel work
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Test fitting a Luxeon Star. I was still waiting on the 3 Lux III stars, this was a Lux I. Plexiglass lens also cut to fit at this stage.
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My home-made 14.4v battery pack, consisting of 12 2500 mA NiMH AA cells. This is 3, 4AA battery packs wired in series. Available at Radio Shack.
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Ryobi 14.4 drill battery charger doubles up as my bike light charger.
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Mounting the 3, 3 watt Luxeon IIIs. I put down one thin layer of Arctic Alumina adhesive... let it set. Then glued the stars to the body of the light using more AAA.
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A look at one end of the body, where I'll have to fit a 3021 Buckpuck, power connector, potentiometer, and wiring!
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