bike_sm.jpg (13051 bytes) Front light battery Pack

 

 

Get a water bottle that has a series of grooves like the one shown here.  These water bottles come with either a wide mouth screw top with a soft rubber nipple or a snap on top with a hard plastic nipple.  The power connector can be forced through the soft rubber nipple type.   For the hard plastic nipple you will either need to drill a  8.5 mm hole in the nipple or thread the bare end cable through the nipple first and then solder the connector.

Cut the water bottle apart with the knife in the axial direction.     Do not cut radially into the bottle.  Cutting the bottle straight up the side will allow the top to be more easily snapped on for reassembly.  (see photo below)

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Soft Rubber Nipple Type

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Cut the two tabs holding the nipple center.   Remove the nipple center.  Save this to reinsert after the cable is pulled through.

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Feed the power connector through the soft rubber nipple.  You might need some pliers to pull it through.  Push in the plastic center over the cable to fix it an help keep water out of the bottle.

Hard Plastic Nipple Type

cap8.jpg (41702 bytes)    cap9.jpg (35464 bytes)

Feed the cable first through the nipple.    Solder the 9V clip on.   Option:  Remove center pin like above and drill a 8.5 mm hole in the nipple. 

The battery holder is sensitive to corrosion so you should take measures to protect the contacts and batteries from rusting.

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lightly oil all the metal parts on the battery holder    lightly oil the ends of the batteries     use inner tube strips to hold the batteries in place

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use inner tube strip to hold the 9V clip in place    get a silica gel pack desiccant               wrap the battery pack and desiccant in plastic folio

DSC04291.jpg (30450 bytes)  

The desiccant can be removed now and then and baked at 90 deg. C for two hours to regenerate it. 

bubble_wrap.jpg (13321 bytes)Put the 10x AA battery holder in the water bottle.  Pack bubble wrap around the battery holder to minimize vibration. 

 

 

 

 

 

 

You can use small cable ties to hold the bottle together for rough terrain areas.    The cable ties are ideal if you charge the batteries in the water bottle.  See this page for charger information.

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You are ready to go.