red_dwarf_art.jpg (8467 bytes)"Red Giant"  taillight
compatible with the 
Supernova
® headlight
or can be battery driven

red_giant_tail_light_sm.jpg (62894 bytes)Introduction:    I have been using a Supernova E-3 Pro hub dynamo driven bicycle head light for over a year on my commute to work and back.  I am happy with it and the light it puts out.   However, I was rather disappointed with Supernova's tail light offering as it does not have a reflector and and only has three small LEDs.  I had been using a 12V GU4 LED, mounted in a Cateye reflector, with the battery mounted in a water bottle.  After discovering the Avago Moonstone 1/2 W LED, I saw that it  had the optimal design and power consumption for a tail light made out of a reflector, like my 12 V version. 

Connecting the "Red Giant" up to the tail light leads of the Supernova E3 light is very easy.   The  Supernova takes the AC power from the hub dynamo and supplies a stable 6.0V DC supply to the tail light leads.    The red lead is "+" and the blue lead is "-".   Technically do you not need to build any diodes or capacitors into the lamp when connecting it to the Supernova E3.   The stand light feature of the Supernova will drive the "Red Giant" as a stand light too.

I made the battery powered design after a friend from our triathlon club had mentioned he thought all of the commercial tail LED lights were not bright enough.  He wanted a brighter tail light for more safety on the road when it was dark, even at the expense of shorter battery life.  The battery powered "Red Giant" is just a modified version of the hub dynamo type.   To keep things simple, there is no switch.   Just clip the "9V" clip on the standard battery pack to turn the light on.  To turn it off, disconnect the "9V" clip. 

Both types of tail lights are extremely bright and visible from a long way off and can be built for less than $5 excluding the hub dynamo or rechargeable batteries.    

On this page you will find out how you too can make the "Red Giant".  It is the perfect companion to your Supernova hub dynamo bike light!

The Reflector
I have found the Cateye brand reflectors work well for this application.   Cateye has three styles of reflector backs.   The "Post" style is my favorite type, then the "slide lock".   The "tapping screw" type should not be used as it would be difficult to bring out the power lead out the back since the "tapping" screw would be in the way. 

reflector_types.JPG (29186 bytes)

The following part numbers should work well:

Post mount:  RR-165-BPR (round) RR-180-BPR (square), RR-290-BPR
Slide lock  :  RR-165-BSLR (round) RR-180-BSLR (square), RR-290-BPR

I have only used the RR-165-BPR and the RR-165-BSLR so far.

The LED
moonstone ASMT-MW62.JPG (3035 bytes)The LED is a Avago "Moonstone" ASMT-MW62 1/2 W 3.7V, which is compact, flat and perfect for the tight space inside a reflector.   It is also has the appropriate power range so as not to take away too much power from the head light.  Being an LED, it is much more efficient than a normal light bulb and will most likely never burn out.  Moonstone LED Conrad 180869-62 1.80

 

 

Other Materials
You will need a 2 conductor 20-22 gauge cable to run to your Supernova tail light leads, two part epoxy to glue the reflector back together and some 2 part epoxy putty to hold the parts in place inside the lamp and a 12-18 ohm resistor rated at 1/2 watt or a little more.  For certain designs, where AC power comes directly from the hub dynamo, a small full bridge rectifier and a small resistor  9-13
ohm will be needed

Applications
There are three possible power sources for the Red Giant:

1.  Used in conjunction with a Supernova headlight:  For this design you do not need to to rectify the AC power from the hub dynamo.   The Supernova lamp provides leads for a tail light and it is a stable 6V DC current.  However, you will need to add a current limiting resistor in the circuit to keep from pushing too much current through the LED and burning it out.   . 

2.  Use with 4 AA or AAA rechargeable batteries:   Rechargeable batteries generally deliver 1.2 V so with 4 batteries you would have 4.8 V instead of 6V.     Here are a few current measurements using fresh charged AAA NiMh batteries.  For a bright light, but shorter battery life you can use the small resistors.   For less light and longer battery life, you can use a larger resistor.   A diode can substitute for a resistor here too. 

Diode                 150 ma
6 ohm resistor  220 ma
9 ohm resistor  150 ma
13 ohm resistor 100 ma

3.  Use with a hub dynamo: AC power output:    In this case you need to rectify the AC power source with a full bridge rectifier.     The  design is detailed below and is very easy to assemble. 

red dwarf circuits.GIF (13791 bytes)

R1 =  12 - 18 ohm (use with Super Nova E3) >1/2W


R2 =  9 - 13 ohm (4 NiMh battery pack) >1/2W
D1 = diode 50V 1A  1N4001


R3 = 9 - 13 ohm (hub dynamo)  >1/2W
BR1 = SMD bridge rectifier 50V 1A B40S

 

Moonstone LED Conrad 180869-62 1.80

Resistor sizing calculation:
R = (VS - VL- VD) / I 
ledres.gif (3705 bytes)

I = 75 - 150 mA  (VL = 3.35 - 3.70 V)

Avago Moonstone SMT-MW62 1/2 W 3.7V, LED Characteristic Curves

ASMT-MW62_LED_characteristics.GIF (18451 bytes)

Red Giant Assembly Type 1 (Supernova E3 Compatible)
DSC06419.JPG (41151 bytes)
Carefully and slowly pry open reflector
DSC06420.JPG (53108 bytes)
Materials wire, reflector, LED resistor,
two part epoxy putty, two part epoxy glue, solder
DSC06421.JPG (55089 bytes)
Pretin the LED (-) lead and form
resistor as shown.
DSC06422.JPG (51469 bytes)
Solder the resistor as shown
DSC06423.JPG (54049 bytes)
Drill a hole in the base as shown.
When a pen knife, score the bottom of the
reflector so the epoxy sticks better
DSC06424.JPG (45695 bytes)
Mix a small piece of two part
epoxy putty
DSC06425.JPG (35668 bytes)
Press the epoxy putty in the middle, and
press in LED and resistor assembly.
DSC06426.JPG (43464 bytes)
Bring the power leads in through the holes
in the base.  Hold the leads down with
two part epoxy putty as shown.
DSC06427.JPG (46480 bytes)
Let epoxy putty cure for 5-10 minutes.
Insulate bend in resistor as shown.
cut (-) lead to size.
DSC06429.JPG (43988 bytes)
Slip a piece of shrink tubing over the (-) lead.  Solder (-) lead to resistor.
DSC06430.JPG (39870 bytes)
Move shrink tubing over the joint and shrink. 
DSC06431.JPG (42658 bytes)
Cut the (+) to size, strip and solder as shown. 
DSC06432.JPG (43147 bytes)
Test connection on 4.8 - 6 V battery.
DSC06433.JPG (46354 bytes)
Mix a little 2 part epoxy glue. 
Lay it in the lens groove.
DSC06434.JPG (44960 bytes)
Place the lens carefully on the base.
Hold down while curing with a piece of tape.
DSC06435.JPG (40480 bytes)
Fill power cable hole with mixed 2 part epoxy
to seal off hole.  Let cure for 24 hours
red_giant_tail_light_dynamo.jpg (48924 bytes)
done!
Red Giant Assembly Type 3
Red_Dwarf001.jpg (63673 bytes)
Pryed open reflector, resistor (13 ohm),
bridge rectifier (type 3), LED

Red_Dwarf007.jpg (46325 bytes)
Drill a hole in the reflector base
for feeding through the cable.
Red_Dwarf002.jpg (59568 bytes)
Straighten and flatten the leads of the
LED and the bridge rectifier. 
For types 1 and 2 just skip assembling
the bridge rectifier.  
Red_Dwarf003.jpg (44051 bytes)
The rectifier needs to be flipped over
so that the positive output lead
lines up on the LED
positive terminal (red dot side).
Red_Dwarf005.jpg (69115 bytes)
Trim the length of the leads to a minimum
and pre tin the leads to help soldering.

Red_Dwarf006.jpg (53355 bytes)
Lay the leads on top of each other
and solder together. ("+" lead to "+" terminal) 
Red_Dwarf008.jpg (48919 bytes)
Prepare the resistor and assemble as shown.

Red_Dwarf009.jpg (50815 bytes)
Insulate the resistor and its leads with
shrink tubing. 

Red_Dwarf010.jpg (49293 bytes)
Scratch up the surface to the two-part
epoxy putty will stick better.

Red_Dwarf011.jpg (46117 bytes)
Mix the two part epoxy putty, place it in the
reflector base, and set in the LED assembly.

Red_Dwarf012.jpg (56822 bytes)
Thread the power cable in the hole in
the base of the reflector. 


Red_Dwarf013.jpg (51355 bytes)
Solder one end to the right terminal
of the rectifier.  Place some shrink
tubing over the left lead.

Red_Dwarf014.jpg (53289 bytes)
Wrap and solder the resistor lead
to the power lead. 

Red_Dwarf015.jpg (31872 bytes)
Shift shrink tubing over the joint.
Shrink tubing on joint.

Red_Dwarf016.jpg (53092 bytes)
Fix the power cable with
two part epoxy

DSC06434.JPG (44960 bytes)
Glue the cover back on.
Hold cover tight with tape while curing. 
red_giant_tail_light_sm.jpg (62894 bytes)
Here is a finished hub dynamo
tail light on my commuter bike.


red_giant_battery_option.jpg (70198 bytes)
Here is a finished battery driven design.
The battery pack is in the saddle bag.
red_giant_tail_light_dynamo.jpg (48924 bytes)
Hub dynamo LED tail light
48 gram with cable.



red_giant_battery_option_1.jpg (56981 bytes)
4x AAA NiMh LED tail light with
battery holder and 9V clip.
4xAA NiMh batteries can be used
for longer life.  92 gram with 4 AAA batteries.