A Lot of Light At Hand
After an old 4-C cell Cateye light I'd used for a decade finally broke, I put a Cateye HL-EL530 headlight on my bike in addition to the 15+ year old EL-500. I was not impressed with the new unit, and the old one, though utterly reliable as a backup and for short range lighting was limping along on a K-2 halogen bulb.
Although the 530 was fairly bright, it uses a magnetic switch inside the case coupled with a vibration-prone magnet on the external switch to turn it on and off. It was very easy to accidentally turn the unit on and run the batteries down. So much so that I eventually put a piece of duct tape on the switch to prevent the problem. In addition, the "Flex Tite" mounting system, though clever, was the removable version of a big zip tie -- a screw driven plastic strap and was sort of rickety (though if you had a non-round section to attach it to, I can see how it would be nice). Quite a step down from the sturdy clamp mounts found on most bikes. To cap it off, the mounting rails that the light head slides into were fiddly -- on more than one occasion the 530 light head would simply bounce off into the street after not latching correctly. The light only suffered scratches, but that's really annoying.
The solution was to stop whining and do something better. I cribbed a design from the "Flashlight" section of the exhaustingly complete (though not recently updated) bicyclelighting.com. The author, Steven M. Scharf, makes the good point that handheld lights are available with scads more power at a fraction of the cost of dedicated bike headlights. What is needed is a sturdy holder for them (not like the wimpy stamped metal ones from years ago, though, astonishingly, those are still being made).
The result was fairly close to Scharf's original design, though with a couple of changes. I could not find the rail mounts that he mentioned, and found that Bike Nashbar has a clamp mount handlebar bottle bracket (NA-HBCC) that works splendidly and has a bar of sturdy plastic to help the mounting assembly. These could be used to mount nearly anything on your bars -- GPS', lights, cameras, whirlygigs, foghorns, pets, children, tollway passes etc. etc.
The only other part you need is a strip of aluminum stock (in this case 3/4" x 1/8" works perfectly), the Lite Clamps from Nite Ize (or something similar -- these are sturdy) and some screws to hold it all together. I went for some M5 x 0.8 stainless cap screws, washers and stop nuts (the kind with the little nylon insert in them that keeps them from working loose). Scharf also used heat shrink tubing to protect the handlbar finish, whereas I just put a turn of PVC tape on the bar.
After the first test run, I remembered the other annoying thing that bike light manufacturers were doing; substituting raw power for engineering. If you look at the headlight on a car, scooter (or one of the older filament bulb bike lights), they have carefully designed optics, creating a broad path of light in an optimal pattern for driving. The new LED versions simply put out tons of light in a spot pattern and depend on the "spillage" to handle peripheral areas, which works very badly. The reality is that you're working with a narrow spot or elliptical path of light, usually at a distance, and there's always a problem with seeing bumps and ruts that are close. You need distance vision and the path leading up to your front tire, which is why my old EL-500 soldiers on year after year; it makes a great close-range light. When I was in grad school and this was all I was using, I'd move the beam up when going faster to see farther ahead. Also a good light for changing tires, finding keys, reading comic books under the covers etc. But again, it was at the limit of what I could get from it using a simple filament bulb.
So, the next stop is to herk up the old EL-500 - an easy task with a nifty -- if pricey -- retrofit 1W LED bulb from Nite Ize (LBR-07-PR1W). It's a drop-in proposition, since there's an internal voltage regulator. So, shelling out a few bucks ($15, actually) and thirty seconds work brought the old favorite into the twenty-first century. In fact, if you root around a bit, you can find these emitters for ~$10, which is cheaper than replacing the light. Be aware that Nite Ize has a lower power retrofit that looks the same and costs less - probably not good for this kind of application.If you were doing this from scratch, it would be cheaper and simpler to find a LED lamp that has a broad short-range beam pattern.
How did it work? HOLY CRAP IS THIS BRIGHT!!!!. The combination is easily as good as a small motorcycle light and maybe then some. I had to carefully aim the flashlight to not blind someone, and the retrofitted EL-500 works wonderfully to fill in the near stuff (and in fact is bright enough to use by itself a lot of the time). I'm not going to post dorky patterns of pools of light like some of the light geeks do, but take my word for it.
The small light can be turned on easily with my thumb and the big one can be too though it's a stretch. The only improvement might be a loop of safety line around the flashlight to keep it seated in case of a really severe bump, but it's shown no signs of coming adrift.
Total cost? About $60 for the whole thing.
- Task Force 3W Headlamp: $25 (Lowes, on sale)
- Clamp: $8 (Bike Nashbar)
- Clips for light: $7 (Nite Ize)
- 1W Retrofit emitter for EL-500: $15 (can be gotten more cheaply online)
- Nuts, bolts, tape, bandaids: ~$4
- Adding an "O" ring to the groove machined in the end of the body of the Task Force light helps it seat in the clamps without trying to slide. There are other grooves that might be used this way to help the clips, but this was all I needed.
- I've added a velcro strap to hold the whole thing in, but so far it's not really been necessary.





