DSC04492_sm.jpg (18617 bytes)Alien Eye LED Mountain Bike Light
Assemlby of the Cateye Spacer

 

 

 

Introduction:    On this page I will show you how to assemble the Cateye spacer (aapter plate), and how to pre-fix the position of the spacer.    When the mount is fixed solid to the lamp, the final forming is much easier to do.    Before baking the lamp, verify that the mount is perpendicular to the axis of the lamp and that the spacer is not rotated to the center line of the lamp. 

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right_left.jpg (24866 bytes)You can choose what side the power connector is on before you fix the base.   If you have a bike computer on the left side of your handle bar then the light will probably be mounted on the right side.   You will probably want the power connector on the left side of the lamp as viewed from the back end of the lamp.   

If the bike computer is on the right side of the handle bar then it would be best to have the power connector on the right hand side. 

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Cateye space plate 533-8730, m4 x 16 mm pan head screw.

 

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Place pan head screw in center hole.

 

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Tighten down a M4 nut.

 

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Place a large washer over the  nut.


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Screw on and tighten the second M4 nut.

 

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Place second washer over the nut.

 

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Optional:   Loctite thread locker.  

 

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With optional Loctite.

 

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Assemble and tighten the third M4 nut. 


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Cut a small piece baking paper and place it over the
slot with the spring in the Cateye spacer.  
This is how it looks when it is done.

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Decide what side you want the power connector on.
Orient the lamp and mark the cooling rib in line
with the two lamp pins.

 

 

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Press Fimo into the center three cooling ribs. 
Note how the FIMO does not go to the
end of the cooling ribs.
The power connector is on the right, so this lamp would be
mounted left hand on the handle bar. 

 

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No material should  get into the cavity for the quick release
or else the quick release function of the  spacer
will not work properly.

 

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Form the Fino as shown in the picturs,
leaving the sides free of material.   
You do not really need to have the material behind the screw,
opposite the baking paper.   

 

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Press the spacer and the light together on the Fimo. 
The screw end should be in the middle of the three
cooling ribs filled with material. 

 

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Make sure the spacer is in-line with the center of the  lamp
perpendicular and that the spacer is not rotated relative
to the center of the lamp.  

 

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The end of the screw should be touch the
aluminum housing housing of the lamp, just below the
the white plastic lamp connector.  

 

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Material overhanging the back end can be removed. 
The lamp will be stronger if this is area is free for the
pre-fixing and filled in at the final molding.

 

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Important:   Check oven temperature before baking! 
It is less of a problem if the oven is not hot enough as too hot. 
Make sure the lamp is in the center of the over, vertically
and horizontally.    Make sure the lamp is not right on top
of the heating elements and that if there is a fan, it is on. 

Place the lamp housing on the shelf as show in the picture.  
Do not place the plastic Cateye  spacer on the metal shelf!    

Bake at 100-110º C for 30 minutes.  Let the part slow cool.  
If the Fimo seems soft check oven temperature and
rebake at proper temperature.  

 

 

Final Forming