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DIY Headlight Case...

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DIY Headlight Case...

Old 09-27-17, 09:11 AM
  #1  
BobbyG
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DIY Headlight Case...

Years ago when I had just one bike, my headlight was permanently mounted and the front fender, and I would carry the rechargeable battery inside with me. When I acquired a second bike I needed a light that could go from bike to bike. I chose a Nitrider Mine at 500 which is your standard hand-phaser sized rechargeable headlight.

the question was then how to carry it in my backpack without having it become scratched, dented, or otherwise damaged in transit.

After measuring, I went to the Dollar Store and bought a plastic lunch container and a dish towel.

Unlike my old headlight set up, the battery in the new headlight will hold a nearly full charge for months. A couple times a summer I will top it off on the charger overnight, and occasionally I will work late or visit somewhere after work and then ride home late after Dark and it is nice to have the headlight ready to go instead of sitting at home like the old one or at least the 4 lb battery.

I now have three bikes each with front and rear blinky's that stay on the bikes those take AAA batteries and I carry a few fresh spares in my backpack, lithium ion as they weigh less and last longer. I also carry my front and rear helmet lights in my backpack and they occasionally get scratched or damaged, but are inexpensive.

As the days get shorter, and night comes earlier, I thought it might be useful or helpful to someone to share my inexpensive, lightweight, and very successful DIY headlight carrying case.
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Old 09-27-17, 09:17 AM
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Originally Posted by BobbyG
the question was then how to carry it in my backpack without having it become scratched, dented, or otherwise damaged in transit.
is this really a problem?
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Old 09-27-17, 09:22 AM
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I wrap my headlight with paper towels & use a ziplock lunch bag. not driving w bike on rear hitch rack w headlight attached. I arrive at destination & attach lights front & rear, sport cam, computer & rear trunk
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Old 09-27-17, 09:25 AM
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Originally Posted by acidfast7
is this really a problem?
Well, I have never tried carrying it without the case; but based on the helmet lights, I could see where over the past 6 years it could have been scratched, or the lens cover broken, or damaged when the backpack is dropped, or falls off the bike, or the bike falls over with the backpack attached, all of which have happened at least once. Also in the winter with extra clothing for both on and off the bike it gets pretty crowded in the backpack and things get smooshed.
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Old 09-27-17, 09:32 AM
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Originally Posted by BobbyG
Well, I have never tried carrying it without the case; but based on the helmet lights, I could see where over the past 6 years it could have been scratched, or the lens cover broken, or damaged when the backpack is dropped, or falls off the bike, or the bike falls over with the backpack attached, all of which have happened at least once. Also in the winter with extra clothing for both on and off the bike it gets pretty crowded in the backpack and things get smooshed.
To be honest, I really like the character of watching stuff get worn out.
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Old 09-27-17, 09:37 AM
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Originally Posted by acidfast7
To be honest, I really like the character of watching stuff get worn out.
I get that. Like well-preserved but unrestored cars, or old metal cameras where the brass shows through from being used. Or like looking at my 55 year old self in the mirror every morning... No wait that's just depressing.
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Old 09-27-17, 09:45 AM
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I normally finish rides in the dark. I put my best headlight on the bars, and have a backup wherever I go. In the cold I did use up the battery on the main light a couple of times. My spare light in the bag is wrapped with bubble wrap, held in place by an elastic. Weight weenie packing materials. The construction of the bubble wrap is just like an old style folding flap sandwich bag, done right, it's rain proof.

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Old 09-27-17, 01:35 PM
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Heck I expect the light I'm running (Cygolite Metro 550) could be dragged 10 miles down the road and still work just fine. That one looks tough too. I sure as heck wouldn't waste any space in a backpack bothering with trying to protect something built like a tank.
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Old 09-27-17, 06:18 PM
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Originally Posted by acidfast7
is this really a problem?
Maybe for bike-specific lights that cost in the 3 digits.

I use an el-cheapo cree zoomable-head, single-18650-battery affixed to my bars with interlocking hose clamps. So (a) it never comes off, and (b) if it did, it's made for knocking around in pockets etc, so it would be pretty hard to damage it.
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Old 09-28-17, 03:25 PM
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With one bike and room for my lights I just keep them all on the bike or my helmet. Problem solved for me.
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Old 09-28-17, 03:37 PM
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I use bubble pouches like this:
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Old 09-28-17, 03:42 PM
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So far no broken lenses, and only light wear on the lights. The biggest issue on one style of lamp was the cord becoming disconnected from the lamp, and everything is epoxied together, so it is really hard to get to where it can be repaired.

I did have one light that a penny fit perfectly in the lamp cover, blocking out almost all the light until I got that penny extracted.

Oh, and those first generation 8.4V CREE battery packs had a tendency to get wet. Temporarily fixed by wrapping a plastic bag around them then put into the case. New ones with waterproof cases seem to be better so far, although the buckles are now half broken, we'll see how the rest of the buckles hold up.

My biggest issue is bumping the switch on my rear blinkies. But, I've not started using USB blinkies, so even an extra hour or two of wasted light isn't an issue.
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Old 10-04-17, 09:59 AM
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I have never once considered or felt the need for a padded enclosure for a light. This is my first time ever hearing about such an idea. For one thing that would take up way too much space in my trunk bag. When I go grocery shopping, I lock the bike and pull my lights and camera off and throw them all into my trunk bag. No wrappers or pads needed. I wouldn't hesitate to throw lights into the front pocket of a backpack. No big deal at all. Certainly nothing is going to break.
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Old 10-10-17, 01:15 PM
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Originally Posted by acidfast7
is this really a problem?
A case of spending to much money on the lights?

That would be way to much work for me. The lights are either on the bike or whatever pocket I have available to stuff them in.
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Old 10-10-17, 01:31 PM
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Originally Posted by cbike
A case of spending to much money on the lights?

That would be way to much work for me. The lights are either on the bike or whatever pocket I have available to stuff them in.
I meant that I buy them to use them and they get used up. I don't worry about scratches.
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Old 10-10-17, 01:31 PM
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Modern LED bicycle lights certainly aren't that fragile. Old filament-based lights maybe, but not LED lights with no moving parts.
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