Build #2 , April 3, 2012: User's Manual Updated + Lens Cover Removal Process

Rate this Entry
Ok, I've made a few edits and additions to the user's manual, including the following description on the lens removal process. I've included the save date in the file name, so you'll always know if you have the latest version. If you follow this link to the Google Site and scroll to the bottom of the page, you'll see the updated file entitled:

All of the first 20 lights have been shipped (except for a few international orders that will be going out tomorrow). For you guys that have gotten lights and care to leave some feedback, the "User Feedback" thread would be a great place to do that if so inclined.

Planning on adhering LEDs boards to housings tonight. I'm getting much faster at the process, so we'll see how many I can get done.
Name:  DS_Lens_Cover_Removal.jpg
Views: 170
Size:  86.0 KB
Tags: None Add / Edit Tags


    I read through it a couple of times. It looks like the Yellow Filter change is not a field operation. You shouldn't just change it any old place you stop your bike when it is getting dark, right? I can see for a commuter this could be an issue as many times during the year, I am riding in the day on my way into work and come back at night. I guess you wouldn't want to change it daily this way.

    Hmm, I wonder if there is some way to fashion a yellow cap cover, something very thin that can be held in place with just the face screw. I look forward to trying out a few options once I get my lights.

    - Roger
    I think I may have muddied the waters with the lens cover removal issue...

    The yellow filter is exactly as you describe. Just a thin (1/8" thick") piece of transparent yellow acrylic. Designed to be very easily and quickly changed out "in the field." I envisioned using it during the day, and then if you find yourself riding into the sunset and beyond hours, just stop and remove it. I'd probably carry the little protective ziplock pouch that it comes in, just to have a nice place to keep it safe while you're riding. I've even had some people tell me they like the yellow so much that they just ride with it at nigh too.

    There's no need to crack the seal on the clear Polycarbonate lens cover to install the yellow filter. Just remove the screw (the clear cover will stay put) and re-install the screw after putting it through the hole on the yellow filter. Easily takes less than a minute.

    In one of my early videos, you can scroll over to 5:25 and see the basic process. This was before the front face o-ring and even before the build-1 sealing process, so the clear piece might look a little loose, but you'll get the idea. Of course, now I ship the lights with an Allan head screw and accompanying wrench, but still give you a Philips option if you prefer.

    I received my lights today mounted them after going in and changing the Superlock mode. Also set up the flashing mode that I desired while riding. So now I have them flashing in the EMS mode, I will make a video of the lights once the weather is better now and I can find a camera man. All I can say is Wow these lights are bright.
    Thanks Stephen, that is exactly what I want. For me, I ride during the day so I will probably keep the yellow on all the time, just nice to know I can take it off. I will get some sort of protective case for it too. I saw that Tap Plastics, local plastic shop, carried the 1/8" plastic yellow, along with a bunch of different colors too

    I can't wait to get my lights soon as I look forward to riding again. Since my accident my family doesn't want me to ride on the streets (mostly I ride on bike trails or very low traffic roads that I have to drive too) , so these lights are a compromise that everyone can live with (no pun intended). So keep up with the blog, I love reading every little detail about the build. It would even be cool to see some build videos - like dipping the batteries in the coating, or soldering the LED boards, or fitting the washers and lenses. Just if you have time.


    - Roger
    Well, I hope there were no lasting injuries from the accident!

    And guess exactly where I get my yellow filter material... yep, TAP Plastics. Fantastic folks to work with. It's a small world...
    Roger! one thing you might look at to make the change a touch faster from clear lense to yellow. I would take a look at color Gel use for stage lighing, it is super thin and you can get it in any color. As for how to secure it I kow that some color gels use to come with a simple for of adhesive so it could be changed real fast. Since I have been out of the music world for a while now, I think some now have a static charge. So it will just stick then be peeled of no more glue. We use to use them with our pars and cans for stage lighting.

    Well, my right shoulder will never be the same and I will have to have it operated on every 10 to 15 years to clear it out, but I am alive and can still ride.


    Thanks for the suggestion. Stephen's solution is what I was looking for, something that could be one in the field in a minute or so without having to remove the whole housing. I would have gotten the same tap plastic that he has and perhaps a longer screw. I was also looking at a Saran Wrap material which I could put on and remove in a few seconds, but it wouldn't be reusable. I use to commute to work on a bike in the bay area so I know that during the winter most people rode to work in the dark in at least one direction which would make the sealing and unsealing of the front lens assembly unreasonable. However, Stephen thought of that and has a quick solution in place. Currently, I work from home and want to ride for exercise, so I will probably just use the Yellow lens full time as I am rarely out after dark any more.

    Personally, I am anxious to get the lights because for me it is the difference between being able to ride and not. Last summer, I lived in the mountains, had only one road to ride with a Very large bike lane. In Oct. we moved back to the city where there is a lot more cross traffic and people not looking at what they are doing. My family doesn't want me to ride in those conditions so I have been pretty much not riding all winter, except for the occasional outing where I can drive my bike to a local trail away from the cars. So for me, these lights represent a sort of freedom for me, a freedom to be able to start riding again.

    - Roger
    I think you should have just one light housing for the front and rear lights.....this would reduce the required inventory. The printing to the sides with the hood over the top (front light) of the lens is more that enough...just a thought Stephen.
    Posted my "quick" review for the DS-1300 and DS-500 lights on the forum if anyone is interested.