Alien Eye LED Mountain Bike Light
Processing Overview

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Alien Eye Mountain Bike Processing Overview Basics (Hybrid design using stand off)
Here is a summary of the basic processing steps for the hybrid design without pictures including optional steps.
  1. Unscrew three screws holding the lens.   Put screws and the lens in a safe place.
  2. On the LED lamp cut off 3-4 mm from the two contact pins.    Remove the silver sticker on the lamp base.
  3. Solder together the switch and power connector.
  4. Solder the switch lead to the lamp and solder the connector lead to the lamp.  Test the lamp with power.
  5. Mask off the non-working surfaces of the lamp with masking tape, or plain tape to keep the housing clean.
  6. Mix 2-3 grams of two part epoxy putty and fix the switch and connector to the lamp base.  Let the epoxy cure5 min.
  7. Mix more epoxy putting and fix the M4x12 mm hexagon stand off in the middle of the base.
  8. Assemble the washer and the screw to the hexagon stand off and fill around with two part epoxy. 
  9. Let the epoxy putty harden for 10 minutes.
  10. Remove the masking tape and temper the two part epoxy in the oven for 10 minutes at 100ºC
  11. Let the lamp slow cool.  Test the lamp with power.
  12. Reapply the masking tape to keep Fimo smudges off the aluminum housing.
  13. Apply Fimo to the cooling ribs (7) flush with the washer on the stand off.
  14. Cut a small piece of baking paper (18x10 mm) the size of the spring/slide on the Cateye mount.   The baking paper prevents Fimo from jamming the quick release mechanism.
  15. Assemble the Cateye mount and see if there is too much or too little Fimo underneath the mount. 
  16. Add or remove material as needed.  Make sure the quick release slide moves freely
  17. Lay the baking paper in front of the washer.   Assemble the Cateye mount.  Make sure the paper and mount are centered.
  18. Apply Fimo around the Cateye base.
  19. Apply Fimo around the Lamp base.  The Fimo can tend to crack if the layer is too thin over the epoxy surfaces.
  20. Smooth out Fimo and remove finger prints by lightly brushing the surface with your fingers.
  21. Remove masking tape
  22. Place lamp in the over with the fan on.  Bake for 30-40 minutes at 100-110ºC.  
  23. Let the lamp slow cool with the oven door closed.
  24. If need be sand the lamp surface with ever finer wet sand paper.   Buff out with jean material and then with flannel.
  25. If you want to seal the lamp, lay a small bead of silicon rubber in the lamp housing.
  26. Assemble lens
  27. Apply silicon rubber in the edge of the retainer ring.  
  28. Assemble the retainer ring.     Make sure the retainer ring sets flat to the lamp.
  29. Screw the three screws back in the lamp.  Wipe any excess silicon away.

Power cable with 9V clip

  1. Remove cover from 9V clip
  2. Remove the existing leads by twisting off the ends of the terminals to the wire
  3. Take a drill tip or grinding stone and remove the nickel coating on the two terminals.
  4. tin the two terminals with solder. 
  5. Solder the power cable leads to the 9V clip.   Take care to make sure the polarity is correct.   The white striped cable is (+).    The (+) terminal is the crown shaped one on the 9V clip. 
  6. Test the connections with the lamp.
  7. Reassemble the plastic cover.