Introduction:    On this page I will explain how to put the "outer skin" on your Alien Eye LED mountain bike light.   The key to a nice finish is to smooth the material evenly and avoid finger prints in the material.    You can avoid finger prints by holding the lamp on the plastic base, the switch, the connector or the aluminum housing. 

As an option, apply masking tape to the non-working surface of the aluminum housing to keep the surface from being smudged  with finger prints from the Fimo.   Remove the masking tape before baking.

Wash your hand before forming the Fimo.    Wash your hands frequently to prevent dirt smudges in the Fimo when working with colors other than black. 

You can make a host of colors using this Fimo mixing chart.  Click on chart for enlargement.  .pdf format

There are already three ribs (number 3, 4, and 5) filled in from the previous process.  
Tightly pack in material in ribs 1, 2, 6 and 7. 
Bring the material forward to the end of the ribs.

Now work in material from the base to the
lamp as shown in the picture.

Apply material to beneath the switch and connector
and form it with the material from the mount.

Fill in material in the step around of the white plastic
connector on the lamp.  Leave the outside of the
switch and connector free of material. 

Fill in material below the switch and connector so that
there are smooth transitions from Fimo
to the components.

Roll out some Fimo in a sheet and cut a piece long
and wide enough to wrap from the under the switch
to the connector as shown in the next picture.  
(A pasta maker works perfect here)

Wrap the strip of Fimo from under the switch to under
the connector.   The strip of Fimo should run parallel to
white plastic connector base on the lamp 

Kneed the Fimo to just cover up the white plastic
connector base of the lamp.   This is a potential entry point
for water and should be sealed up with Fimo.   

Smooth out the Fimo with light finger pressure.  
Always support lamp on non-Fimo surfaces,
such as the aluminum housing, the base, the switch,
or the connector.

This is how the Fimo surface finish should look before baking.

All surfaces are smooth and free of finger prints. 

Check for finger prints and non-symmetrical
surfaces between the left and right side.   
Since the Fimo does not harden on its own, you have
lots of time to get the form like you want it. 

Remove any masking tape you might have used to
keep the aluminum housing clean.

Bake the lamp out for 40 minutes at 100-110º C.
Place the lamp in the oven on the aluminum
housing as shown.   Make sure the shelf is in the
middle of the over and that the fan is on. 
Let your little Alien slow cool when the baking time is over. 

Assemble the lens.   Be careful of finger prints. 

Assemble the outer trim, making sure it
sits flat before screwing it down.

Assemble and lightly tighten the three screws.

You are done!

1.   300 grit wet sand paper
2.  600 grit wet sand paper
3. 800 grit wet sand paper
4. 1000 or 1200 grit wet sand paper
5.  Polish with denim material
6. buff out with flannel material.