LED End Caps for Bicycle

Get my Fusion 360 file for this model here.

I'm glad to see your makes!

IDEA

I was riding my bicycle at night. In front of were a some people, I used my bell and they went to the side but someone still got hurt because he didn't see my handlebar. So I thought of making some lights at the end of my handlebar so the people can see me better.

INSTRUCTIONS

1. Get all the needed parts!

Switch(10 pcs.) - http://ali.onl/1tWm

LEDs (5 colors x 20pcs.) - http://ali.onl/1tWA

68R resistors(100 pcs.) - http://ali.onl/1tWS

2. Take the self-locking switch and shorten the pins. Cut off the pins of the housing.

Cut off about a half of the length of the pins.

3. Insert the switch into the "LedCaseCover.stl" part!

It can be hard, if you can't get in the switch then cut off a part of the small edges which prevent the falling out of the switch.

4. Take the "Button.stl" part and glue it onto the switch!

You can use super glue or hot glue.

5. Take the LEDs and bend the pins of them.

Cut the legs of the LEDs to the needed length AND DON'T THROW THE CUT OFF PIECES AWAY!
The dimensions on the picture doesn't need to be the exact same!

6. Take the "LedCase.stl" part and insert the LEDs into it!

The long legs need to be on one side, the short on the other side.
Bend and shorten the lefgs of the 68R resistor!

You can use some super glue or hot glue to secure the LEDs(optimal).

7. Solder the legs of the LEDs and the resistor!

Don't hold the soldering iron at the pins for too long because the printed part can melt!

8. Creating a connection to the + of batteries.

Now we will need the metal pieces from step 5. Bend one of them like the letter n, heat it up using a soldering iron and melt it into the 3d printed part(see picture). Then take another metal piece and solder it to the most top pin of the switch and the metal piece you just melted in.

9. Take a nail, heat it up and create a hole next to the switch pins, because I forgot to add a hole to my model.

10. Now solder wires to the LEDs!

11. Insert cables into the holes on the "LedCaseCover.stl" part.

The + of LEDs must go through the hole youjust made and - through the hole which was printed.

12. Now you can close up the LedCase.

I used some 2.6mm diameter and 5mm length(thread) screws which I found in my box which is full of different screws.
After you closed everything up take two batteries each 1.5v and test if everything works fine.

13. Solder the cable(in the hole you made) to the middle pin of the switch.

14. Insert the cable into the hole on the tube for batteries!

15. Put some glue onto the cylindrical part around the switch and slide it into the the long tube.

Match the holes for the cable so it doesn't break.

16. Take the "BatteryCover.stl"part and insert a cable into it.

Place the threaded part towards the end of the cable.

17. Take a spring and wrap the cable around it, then solder it!

18. Insert the spring into the hole on the printed cover!

19. Place the cable into the cable channel and wrap everything up using some isolation tape!

Don't wrap too much layers, it can issue a too big diameter of the insert.

20. Enjoy your creation and ride safe!

Sorry if I have mistakes or typos in my text!