Stephen

Build #3 Update: Oct 30, 2012, First 26 Assembly Part 2

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Build 3 Shipping Tally to Date (as of 11/13):
Taillights: 19
Headlights: 6
On deck (last order from the first batch)... Jeff C.

Was burning too much time trying to figure out how in the world to change the BLOG settings to allow more than 10 attachments per entry, so I'm just going to continue it here.

Assembly steps and completion status for first batch of 26 (19 tail, 7 head):
1. Clean housings, and install power wire o-ring with 3M weatherstrip adhesive. (30 min - 100% Complete 10/26)
2. Bond LED boards to housings with Arctic Alumina. (45 min - 100% Complete 10/27)
3. Epoxy the power switch to all the lids, solder wires, and strain relief. (1.5 hr+overnight cure - 100% completed 10/29)
4. Install and solder series jumper wire to main LED boards. (1 hr - 100% completed 10/28)
5. Install lid o-rings (lightly lubed with silicon). (30 min - 100% completed 10/28)
6. Cut to length, strip, and install power wires into housings. (1.5 hr - 100% completed 11/1)
7. Solder power wires, LED drive wires, and switch wires into PC board. (1.5 hr - 100% completed 11/2)
8. Install PC boards into housings with loctite and thermal paste. (1.5 hr - 100% completed 11/9)
9. Install Lids with loctite on screws. (45 min - 100% completed 11/9)
10. Solder Pos (+) and Neg (-) drive leads to the LED boards (1 hr - 100% completed 11/9)
11. Install front face o-ring for sealing lens cover. (20 min - 100% completed 11/9)
12. Grind 0.005" off top edge of 7 headlight lens covers (30 hr - 100% completed 11/12)
13. Install Lens o-rings into lens cover (lightly lubed), install lenses, install lens cover. (1 hr - 100% completed 11/12)
14. Install modified H27 quick-release spacer onto extender bars and mate with light body. (1 hr - 100% completed 10/30)
15. Install extender bar onto the light body (20 min - 100% completed 11/12)
16. Cut spring rubber spacers for H32 clamps (seat stay option). (1 hr - 100% completed 10/30)
17. Check programming, leak check, and burn in (1 hr - 100% completed 11/12).

Here's another good picture of the extender bars, showing the two different lengths. The headlight bar is about 3/8" shorter (at 2.5 inches) than the taillight bar. I should clarify that the SHORTER bar goes with the headlight, and the longer bar goes with the TAILLIGHT. The extra length on the taillight extender bar actually allows the light head to swivel 360 without hitting the quick release bracket. Note also that in this picture, you're seeing both sides of each bar. It's only the perspective that's making it look like four different lengths.
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Update 11/1/2012:
Took a break from the lights last night (sort of) to do some "trick-or-treating" with the kids in the neighborhood. Perfect night in the 50s, almost a full moon. Good time had by all. Enough sugar to kill a horse. Afterwards, standing around a fire pit in the cul-de-sac with all the folks in the neighborhood, someone pulled out their $1.50 Harbor Freight flashlight to look at something, and I casually mentioned, "Here, do you need some more light? (pulled DS-1300 out of my pocket)" Sure... followed by a L5 blast of light filling the whole street, followed by the standard dropped jaws and comments like, "Geez! Better turn that thing off before all the air-traffic gets redirected to land in the neighborhood." Pretty funny.

Good progress tonight. Got all of the taillight housings finished up to step 8, with the 7 headlights to follow. The picture below shows a taillight housing with the controller board and all the wired connections in place. The next step of actually mating the board to the housing and routing the drive wires out the front is very quick.
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Update 11/2/2012
Got a handful of lights completed this evening, but also ran into a snag... had to happen at some point, things were running too smoothly. Nothing too major, just a time consumer. Apparently the dimensions on the headlight lid were just a few thousandths off (exactly... 0.005"), which requires that I painstakingly remove about 0.010" of material from the top surface of the lens cover in order for it to fit correctly. Tape over the lens cover, belt sander, etc. No such problem for the taillight. Hopefully I'll get the process down so it doesn't take 45 min just to do one.
Shown here is the inside view of the headlight before soldering the LED drive wires and installing the lid.
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Update 11/3/2012
Unfortunately I had to devote the time tonight into remediation of the headlight lens cover tolerance snafu. Amazing how long it takes to precisely wrap 35 individual lens covers. Off to the belt-sander. The parts were made exactly to specification, and in this case I just simply failed to take into account the normal tollerancing error like I should have.
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Update 11/4/2012
Making good progress on the taillights, still need to finish grinding down the headlight lens covers. Will be shipping out units all this week. Below is a picture of the lights at step 10. Everything is buttoned up and the drive wires have been trimmed to length. They have to be stripped, bent, and soldered, all of which is a very tedious process to avoid damaging the LEDs.
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Update 11/5/2012
Moving right along tonight. Got all of the remaining taillights down to step 13. Just need to install the lens orings, lube the inner "race" on the lens cover and screw it down. Also got two more headlights completed, just waiting for me to modify the lens covers.

Update 11/6/2012
Finished up the first batch of taillights tonight. Shipping out as fast as possible. Should have the first 7 headlights done by the end of the week.
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Update 11/7/2012
Didn't work out for me to finish any more headlights last night (LOUD belt grinder), but I did get power wire o-rings installed on about 50 new housings.

Update 11/9/2012
Looks like the lens cover modification process is going to work acceptably well, just kind of slow. Got all of the first 7 headlights to the point where they are ready to accept the lens cover. Pretty much just need to trim three more, then it's just a matter of getting everything boxed up. Simultaneously working on the next batch of lights and will start a new thread for those. Took a few "glamor" shots of the headlight and will post here as well as more in the Photos Forum.
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Update 11/13/2012
Well the first batch finished up nicely. Overall I'm pleased with the assembly process. Cooling on the headlight was good, but now even better with the new housing design. The whole process is still more time consuming than I'd like, but I'm getting quicker the more that I put together. Planning on building a larger batch next with around 25 taillights and 15 headlights.
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Comments

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

    Just kidding! Very excited about the DS-500!
    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
    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.
    Do you have a running list so maybe I can see what spot I'm in????
    Quote Originally Posted by ebuzz
    Do you have a running list so maybe I can see what spot I'm in????
    Sure, just send me a PM or email, and I can let you know. Thanks!