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Vintage Honda Owners,
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LED Headlight Bulb
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MBellRacing
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Joined: 15 May 2010
Posts: 149
Location: San Mateo, Ca

PostPosted: Sun Dec 11, 2011 3:23 pm    Post subject: LED Headlight Bulb Reply with quote

...I know, I know, it's been discussed, but I have something new, unconventional, and honestly slightly less than idea here. A morning-wasted brunch conversation with my electrical engineer-turned CEO father has given me an idea. There are still vague areas of the process, but I've done at least some homework for anyone else possibly looking to get great lighting with huge energy savings-- we're talking CHARGING THE BATTERY WITH THE HEADLIGHT ON!

Luxeon makes a Rebel series of high-ouput LED emitters that can be batched by them, or you. They are WAY over the legendary 100lumen/watt mark with their multi-emitter products like this one:



http://www.luxeonstar.com/Cool-White-5650K-7-LED-40mm-Round-Assembly-p/sr-02-wc310.htm

It puts out ~1700 lumen at 700mA which is the max they recommend, though they show information for up to 1000mA, outputting 2240 lumen. That is comparable to the average car's halogen headlight. I don't know what sort of lumen the stock CB77 headlight produces, but it doesn't hold a candle (pun) to most automotive bulbs. The part is that the LED pack will use only between 8-11 watts.

Luxeon also sells the proper controllers that are externally dimmable which means you can retain a real high/low beam. They currently have two useful cluster lenses that aim the beam pattern in either a 12 or 50 degree spread. I chose 50 degrees, personally, to see if I can use some of the stock diffusers in the the Honda headlight lens and to avoid blinding oncoming traffic.

Now the annoying parts of the conversion. First off, the LED pack and board are 40mm in diameter with a round, flush-fitting heat sink. This reveals two issues: the bulb fitting in the headlight rear backing/reflector is less than 40mm and the 40mm round heat sink doesn't offer great heat spreading. The first issue is resolved by making a custom back to the headlight back and/or by removing it from the lens to mount the LED "bulb" from the inside. The heat issue is one I'm going to have to play with. I'll assume it gets pretty hot inside that headlight, especially when the better part of 2000 lumen of light is being produced. We'll see if those LEDs can stand up to it!

Without need for the headlight backing as a reflector, I figure it may be possible to drill some holes in it to let some heat into the hollow, steel, slightly ventilated actual headlight case that mounts to the fork ears.

Parts are on order as well as an aftermarket headlight (so I don't booger up my factory one), I guess we'll see!
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jensen
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Joined: 12 Feb 2008
Posts: 1143
Location: netherlands, huizen

PostPosted: Sun Dec 11, 2011 6:25 pm    Post subject: Reply with quote

Hi,

What about these ? I have used those in several projects, next to the Philips lumileds.
And I'm also thinking of making one myself too.

http://ce.citizen.co.jp/lighting_led/en/products/index.html

Jensen

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assembly of Japanese motorcycles requires great peace of mind (Pirsig)
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MBellRacing
honda305.com Member


Joined: 15 May 2010
Posts: 149
Location: San Mateo, Ca

PostPosted: Sun Dec 11, 2011 7:41 pm    Post subject: Reply with quote

Those definitely aren't bad emitters, I'm just concerned about the complexity of mounting multiple high output LEDs in that form. I'd rather do it with ready-made 7 LED boards. It might also be hard to find optics for it.
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jensen
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Joined: 12 Feb 2008
Posts: 1143
Location: netherlands, huizen

PostPosted: Mon Dec 12, 2011 1:13 am    Post subject: Reply with quote

Hi,

Check Fraen: http://www.fraensrl.com/prodinfo.html
I use them a lot, good quality and fast delivery (at company's),

Jensen

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assembly of Japanese motorcycles requires great peace of mind (Pirsig)
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MBellRacing
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Joined: 15 May 2010
Posts: 149
Location: San Mateo, Ca

PostPosted: Thu Dec 22, 2011 4:46 am    Post subject: Reply with quote

Update:

Got a spare Honda-knockoff sealed beam headlight for $20 and received the LED board, the lens, and the controller the other day!





The plan is to make a custom base out of some thin aluminum which will double as a heat sink. The bottom of the spare headlight reflector will be cut off enough to pull out the old bulb and fit the LED set in. I'm going to try and get the LEDs as far back in the headlight as possible to use some of the factory diffuser/lens to spread some light on the road.

I've been very busy with the holidays and working on another project for the same bike. Why take things in steps when you can work yourself to pieces doing them all at the same time!?!
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Mike Mullins
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Joined: 02 Aug 2007
Posts: 246
Location: Demotte IN

PostPosted: Thu Dec 22, 2011 9:19 am    Post subject: LED Reply with quote

This is VERY interesting ! I am really getting started on my '66 Super Hawk cafe project, and had sourced a headlight with an H-4 bulb. I was wondering how I was going to keep everything lit up and charged. A possible alternative here ? LED's on all corners of the bike possible ? Being electrically challenged, I am looking forward to getting my horizons expanded. Keep us posted. (Just out of curiosity, is the cost of such a setup expensive ?)
(see attached photo of project in its present state.)
Mikeyrx



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"a free motorcycle is a bottomless hole intended solely for money"
66 CB 77
76 BMW R75/6
99 GL 1500 trike
75 & 79 XS 650's
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Snakeoil
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Joined: 04 Aug 2010
Posts: 1090
Location: Upstate NY

PostPosted: Thu Dec 22, 2011 10:33 am    Post subject: Reply with quote

Great thread! I know little to nothing about LEDs and how to build a proper headlight. But I'd like to throw out a few questions, to serve as clarifiers if nothing else.

Couldn't you mount the LEDs so that they shine to the rear and into the reflector to get good road coverage? Isn't that what they do with some of the high tech incandescent lights? I say this because I understand that LEDs are uni-directional so unless you angle each one at a different angle, you only get a narrow beam of light. Or has that changed with technical developments/improvements?

Could they put two sets of LEDs on one board so you could use two sets of reflectors to give you the hi/lo beam requirement?

And here's a hair brained thought off the top of my head. Mount the hi beam LEDs to a board that surrounds a normal bulb. The bulb serves as the low beam and the LEDs as the high. This would allow you to run the LEDs in the daylight and when not in traffic in the dark and the bulb is just run when in traffic at night.

regards,
Rob
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