Blog Comments

    Do you have a running list so maybe I can see what spot I'm in????
    Quote Originally Posted by pmartin4665
    Follow-up from purchase on 9/26/11 -
    Hi Stephen: I just wanted to convey my appreciation for such a great product - the Design Shine headlight/taillights are phenomenal! I originally purchased them for my Trek FX+ hybrid bicycle that I used for a year to commute to work (12-15 mi. each way) but I fell in love with a 2011 Trek Madone 4.7 road bicycle and now use that for commuting as well as pleasure. I could send some photos of the set-up; it isn't to uber-dorkey but I'm sure the purists would scoff at it . . . until they try bicycling at 5am in the dark on a cold November morning!!!!

    You make an incredible product and I'm extremely satisfied with my purchase! Please continue the great work!

    Sincerely,
    Paul
    Thanks Paul! Glad to hear that you're still enjoying them. I'm going to copy your comments here over to the feedback forum as well.
    Follow-up from purchase on 9/26/11 -
    Hi Stephen: I just wanted to convey my appreciation for such a great product - the Design Shine headlight/taillights are phenomenal! I originally purchased them for my Trek FX+ hybrid bicycle that I used for a year to commute to work (12-15 mi. each way) but I fell in love with a 2011 Trek Madone 4.7 road bicycle and now use that for commuting as well as pleasure. I could send some photos of the set-up; it isn't to uber-dorkey but I'm sure the purists would scoff at it . . . until they try bicycling at 5am in the dark on a cold November morning!!!!

    You make an incredible product and I'm extremely satisfied with my purchase! Please continue the great work!

    Sincerely,
    Paul
    Whoa whoa. No breaks allowed once the build has started. Get back to work.

    Just kidding! Very excited about the DS-500!
    The flash while using the headlights is awesome! Excellent for getting the attention of drivers!

    Great work Stephen!
    Yes, final assembly really entails "marrying" up the housing (with LEDs) with the pre-wired lid assembly.

    Strip power wire after inserted into housing
    Solder power wires to control board (VERY tricky)
    Apply thread lock to control-board hold-down screw
    Apply MX2 to thermal mounting tab
    Arrange wires and mount control board into housing with 2-56 screw (torque appropriately)
    "Fish" power wires through the center holes of the LEDs
    Trim power wires to length
    Strip and Tin power wires
    Precisely bend (90 deg) power wires to mate to LED boards
    Solder power wires to LED boards

    And that's before even touching the lens cover or the front face o-ring, or sealing up the lid, or mounting the extender bars, cleaning the LED domes, cleaning up the housing, leak checking, programming, testing, packing up orders.... whew. I actually took some video of prepping the o-rings and assembling into the lens cover. That process alone is at least 5 minutes. I have a whole NEW appreciation for assembly line workers now.
    Look forward to the new posts. When you say "final assembly" you mean the whole thing once you have the parts, or the part after the electronics are put on-board? Also, I personally would like to see some pictures of you putting things together. For example, the front gasket. You said you made some new tools to make the job easier, be cool to see what they were.

    - Roger
    Yes... building lights like a mad man this weekend. Still amazed at how long it takes for final assembly. I do have several good ideas for new posts coming up, so stay tuned.
    Stephen,

    Its been a while since your last post, anything cool going on?

    - Roger
    Wow, what bad luck. I hate it when things like that happen. I hope tonight goes better.

    - Roger
    Yes, it's pretty tough. Wasn't having the best luck last night, though. I was actually finishing up your taillight and was about to close up the lid, but the screw holes didn't line up... I have no idea how, but somehow a single build #1 lid ended up in my build #2 lid box, and I managed to miraculously pick that lid for yours, so I ended up having to remove the electronics, un-solder, modify another lid, re-solder, re-install, etc. I still managed to get 15 taillights done with electronics installed and power wire connected, but I was hoping for all 26. We'll see how it goes again tonight!
    SP
    Wow, just 1 hour a night, must be hard to get it all done. Still, I bet you can get into a groove when doing the same task over and over.

    - Roger
    Yes, it's really tough. I have to be pretty rigorous to stick to a schedule... like, OK I'm going to work for 1 hour tonight. Always later in the evening after kids are in bed.
    Posted my "quick" review for the DS-1300 and DS-500 lights on the forum if anyone is interested.
    50 additional lights?! Where do you find the time? I can imagine your wife and/or kids giving you the bad eye look.
    Very Cool. Well, I'm taking my bike in to be tuned today since it will be raining for the next 3 or 4 days - then on May 1st, I'm having a professional body geometry fit done so I finally get comfortable on my new bike (3-years old) as I was on my old bike that I had for 15-years before my accident.

    So I'm getting prepared to be able to really start riding again and with your lights, be able to do it safely!

    - Roger
    Exactly right. First I go through my existing build notes and make a note of any custom length orders, then I cut all of the (pre-screened) connector wires to length, "shape" the outer insulation (so it can be started through the o-ring and housing). Then once it's through the hole, strip the outer insulation (about 1"), strip the insulation (about 1/4") on the inner two conductors, and finally solder to the power board.

    Got all the series jumper wires soldered in place for the taillights last night. Plan on finishing the jumper on the headlights tonight, then starting on the power wires.
    SP
    Looks good, what's next? I think it is wiring the power cords into each case, right?

    - Roger
    Very cool, bet it is a large pyramid! Best of luck! Remember, you still owe us pics of the little truck zooming down your street with the lights on it!

    - Roger
    Going quite well... roughly 26 headlights and 26 taillights remain after the first 20. All the remaining lids are finished, and all the LED boards have been adhered to housings. All the lens alignment holes have been drilled. Plan on soldering the series jumper wire this evening. I'll try to post a shot of all 50+ housings later this evening.
    Thanks,
    SP
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