Improving a $3 LED bar end light

These lights can be found on ebay for less than $5 (each), but just a little effort can improve their light output and reliability. I have these mounted on my forks instead of my handlebars, but somehow the vibration shook one of the lenses off and I lost it. While I have an extra one on order for about $3 with free shipping (slow boat from China), I decided to unscrew the lens I still had.

The end cap is glued on, but it doesn't take much effort to pry it off with something thin. I used a razor blade, but a thin screwdriver should work as well. Painting the end cap white to reflect more of the light would help, but I decided to leave it off so I have 1 fewer item to lose when the glue gives way in a few years.

I drilled a shallow hole in the center to catch and reflect some of the light. A counter sink bit would work really well since it has a heavy taper, but I couldn't find mine, so I just used a 1/4" drill bit and went about 1/2 way into the lens. There is a predrilled off center hole that the manufacturer must have intended for refraction but it shouldn't affect my mod. I suspect they save the more centered drill hole just to differentiate the more expensive products.

Using fine sandpaper, lightly scuff the surface to diffuse more light. Put some locktite on the threads and screw it back on to the base.

Increased brightness as well as improved visibility from the side

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Old Car and Bike rambling

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