MR16 E-Bike Light Enhousing

thingiverse

I designed a simple light housing in OpenSCAD using MR16 LED spots that had been collecting dust from my previous bike lights. The parts were printed in PETG with 100% infill, and it remains to be seen how well they will hold up outdoors. Even today, despite the abundance of cheap LED lights available on AliExpress and DealExtreme, I believe MR16 LED inserts are still a viable option. They're extremely affordable, can run from 3S to 4S Li-ion packs, and can easily be connected to an e-bike battery using a DC-DC step-down converter. I soldered two wires directly to the MR16 insert and tied a knot in the cable to prevent it from coming loose. For securing the light inside the housing, I used some marine sealant that I had lying around, but anything should work. Mounting the light to the handlebar is straightforward using any of the many adapters available from Busch & Müller, Lupine, Supernova, and others. Update: After accidentally breaking one of my MR16 lights' holders during a mishap, I designed a repair holder that can be easily attached to a light with small screws and epoxy. I also created a modified housing with air slots for more powerful LED lights like the 7W Philips spot I recently purchased.