These are the housings before any prep work, there are some dents in the front housing, and someone drilled a hole through the side of the housing to install a switch.
I will wire brush the housings, try to fix the dents and extra hole, and repaint as necessary. First I need to remove the internals and prepare them for LED lighting. I'm going to use the same approach previously used on the 1949 Comrade. Its been installed for over 3 years and I know it works with the Dynohub. There is a wealth of information and opinions on-line for LED bike lighting. The circuit I used for the Dynohub is a simple variation of more sophisticated options. In addition to the LEDs, it uses only two components, a Bridge Rectifier, and a Capacitor. Also needed is a Heat Sink for the high powered LEDs. From browsing the web, these seems to come in many variations, from commercial products to DIY versions using a bolt and some washers. According to the "experts" a heat sink is needed to draw heat away from the LEDs to prevent damage. I will make some heat sinks similar to what I used on the Comrade, but made smaller fit the Sport housings. In addition; they will provide a mount for the LED's within the vintage housings. These are the heat sinks made from aluminium rod to replace the bulbs, they are sized to be a friction fit within the original bulb housings.
|Rear light heat sink.|
|Heat sink for rear light inserted into bulb holder. The LED will be mounted to the face of the heat sink.|
|Front light heat sink|
|Front light heat sink inserted, the LED will mount to the face of the heat sink.|
This is a patch to repair the hole that was drilled into the lamp housing by a previous owner. With a little Bondo and some sanding and it will be unnoticeable. I also had to shorten the screw that fits into the rear of the housing because it was interfering with mounting the circuit board. I will use J-B Weld epoxy to affix it to the housing.
|After Bondo and sanding|
|Shorten screw, will be epoxied to rear of housing|
The next "LED Lighting" post will cover building the LED circuit board and mounting. Please share your comments and experiences.