About six months ago I fitted an elderly headlight onto the Xtracycle, to be connected in due course to the Dynamo I’d already built into the wheel and the new light fitted on the back. I only needed to add a switch, so it was an easy job.
I got the switch last week.
The problem -apart from a chronic lack of confidence- was where to put the switch. I’d been searching for most of the winter for a small box of some sort to fit the switch in, preferably with a removable, waterproof lid. It appears that this is an under-served area of the consumer market.
I could have bought a new front light of course, with everything in one casing and probably better optics, but come on.
Eventually I came across these tins for cough tablets. They’re a bit bigger than I wanted but they’re made of aluminium, and they have a lid so I can get at the internal gubbins easily when something goes wrong or in some wild moment I decide to install a capacitor for the front light.
Cutting the lid was easy enough with a normal craft knife, the hole is not quite as round as the screw thread, but it’s hidden by the switch and I trust you not to tell anyone. While working in the shop I drilled a hole in the base of the tin and fitted it to the back of the forks. Unfortunately the tin didn’t fit under the crossbar. The system worked fine as long as I only wanted to ride in a big circle.

More drilling and fitting the tin a bit lower down produced the deluxe version* above. I’ve been riding with it for a couple of days and it doesn’t get in the way although it does look a bit strange, so now it’s time for a trip to the paint shop.
To be continued…
*’Deluxe’ defined as ‘usable in a straight line’.

5 comments
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May 7, 2011 at 7:48 pm
the_big_smile
This look like an interesting solution.
Are you sure, the can mounted horizontally like this will withstand the vibrations for a long time?
But you are right, it is not necessary, to buy a new light with a switch build in.
May 7, 2011 at 10:11 pm
Andy in Germany
Hi Big Smile, thanks for dropping in…
I’m not sure if it will stand up to life on a bicycle, we’ll have to see. Usually I allow anything I get for the bikes a year of testing to see how they handle different conditions, or if there’s a ‘running in’ phase. If it doesn’t seem to be doing its job I’ll have to look for another casing from somewhere like Conrad, but it’s worth a try…
May 9, 2011 at 10:51 am
Accidental hermit
Oooh. Very cool. And yes, it’s odd how in this world of excessive packaging, it’s still hard to find cases that are just right.
May 9, 2011 at 11:13 am
Andy in Germany
Thanks AH…
Strange isn’t it? I guess we’re not only in the world of wasteful packaging we’re also in the world of wasteful disposable packaging…
I’ve got a little further with the project now, although I’ve got some kind of man-flu today and I managed to drop the half painted can on the floor so I’ll need to redo it…
May 21, 2011 at 8:05 am
Let there be light… « People Powered
[...] 21, 2011 in Bike parts, Bikes, Cycling, Vaguely decent photographs, Xtracycle I muttered last week about the project to make the Xtracycle’s hub dynamo actually produce some light for the [...]