MOTOBRICK.COM
TECHNICAL MOTOBRICK WRENCHING In Remembrance of Inge K. => Project Classic Motobricks => Topic started by: bobvans on March 02, 2021, 11:31:32 PM
-
Back when I got my '86 K100 I wanted to improve safety a bit by adding an LED brake light that strobes when brake is applied. It was a bit of a hack job in that I bought one of the standard tail lights Custom LED offered and cut up my tail light to make it fit.

IMG_1002.JPG (43.87 kB . 432x576 - viewed 1333 times)
Now that I have a'96 K1100, I wanted to add the same capability but make it look stock and have it light up the entire tail light like this picture someone posted somewhere...

Tailight.JPG (50.41 kB . 768x576 - viewed 1199 times)
But I want it to strobe like this... except I won't use the turn signal feature since I want to continue using the original turn signals.
https://www.youtube.com/watch?v=neXLC73tgmU
So I bought a new tail light from Max BMW, cut it open with a dremel and sawzall.

File_000.jpeg (62.03 kB . 768x576 - viewed 1156 times)
And am now working with Custom LED to have a... you guessed it, custom LED board made up to hopefully somehow fit into the tail light. Here's the board design we settled on...

Custom LED R3.jpg (28.2 kB . 768x396 - viewed 1190 times)
-
:popcorm
-
https://www.skenelights.com/online-store/P3-Lights-p199537706
-
https://www.skenelights.com/online-store/P3-Lights-p199537706
I've seen those but really want the entire tail light to strobe and be super bright. Hopefully I sized the board correctly and can get it all back together and look decent :laughing4-giggles:. I'll provide an update in a few weeks when I get the board.
-
Will your board act as running lights as well as a strobing brake light?
-
Will your board act as running lights as well as a strobing brake light?
Yes, running lights, brake lights, and integrated turn signals (if you want). The strobe affect on braking is selectable... 11 different options.
[ Invalid Attachment ]
-
11 options! God bless America—or elsewhere—whichever is applicable!
-
11 options! God bless America—or elsewhere—whichever is applicable!
Ha ha... can't have too many options :laughing1:.
-
Can I have three quick flashes, then three slow flashes, then three quick flashes, repeat?
-
Can I have three quick flashes, then three slow flashes, then three quick flashes, repeat?
That would be with the 4 way flashers option :laughing1:
-
Despite the term SOS, I believe the correct pattern is 3 quick, 3 slow, 3 quick, 3 slow, etc.
-
Received the custom LED board on Monday. Now the challenge will be to cut away the right amount of the tail light's plastic support structure to fit the board while maintaining enough structural strength of the overall assembly. I think a band saw would make the task a lot easier. May need to take this to work and see if I can get into the model shop.
[ Invalid Attachment ]
-
[ Invalid Attachment ]
[ Invalid Attachment ]
I want to get it mounted in this location so need to cut away the part of the housing that's in the way.
[ Invalid Attachment ]
-
Started cutting away on the tail light assembly. A ways to go yet but this gives me a feel for how it will turn out. Looks like the structure should be in good shape, even after the hacking is done.
[ Invalid Attachment ]
[ Invalid Attachment ]
-
How many of those lights serve as brake lights, how many serve as tail lights and how are they arrayed, or do they all have a double function?
-
How many of those lights serve as brake lights, how many serve as tail lights and how are they arrayed, or do they all have a double function?
I haven't confirmed yet, but they're all supposed to be double function (running and brake lights). For turn signals half would flash on and off.
I'm chomping on the bit to due an A/B compare... so may do that before I get the actual retrofit done. On that note, I'm going Dremel vs band saw and my Dremel crapped out on me... may need new brushes :idunno:.
-
:popcorm "Cuuuul".....
-
Got my Dremel back online so did some more cutting. It's almost there... just a little more trimming to level out the surface the board will lay against.

Custom LED 30.jpeg (63.45 kB . 768x576 - viewed 1041 times)

Custom LED 31.jpeg (33.64 kB . 768x576 - viewed 987 times)

LED Board 12.jpeg (54.19 kB . 768x576 - viewed 1017 times)

LED Board 10.jpeg (38.11 kB . 768x576 - viewed 1046 times)
-
After a bit more trimming with the Dremel, I've got it to where I think it needs to be. Decided to close off all the openings with some pieces I cut from electrical boxes. Hot glued them in place.
[ Invalid Attachment ]
[ Invalid Attachment ]
Next I need to drill a couple of holes for a couple of mounting screws along with adding something for the screws to screw into. I'm going to try using the two drilled screw bosses from the electrical box.
-
I wasn't sure about what to do with the brake light "magnifier" part of the tail light. Then remembered that the entire tail light will be the brake light so decided to just cut it off and leave only the clear lens part for license plate illumination. I glued it with a combination of super glue and hot glue... super hot glue :laughing1:. Actually just super glued it on and put the hot melt over the joint for good measure.

Magnifier 01.jpeg (82.79 kB . 768x576 - viewed 998 times)

Magnifier 03.jpeg (82.92 kB . 768x576 - viewed 1016 times)

Magnifier 02.jpeg (59.21 kB . 768x576 - viewed 970 times)
Just to add... I had to trim the inner walls of the red lens to allow the lens to fit over the circuit board.
-
Looks interesting. Keep posting.
-
Looks like using the screw bosses off the electrical switch box is going to work nicely. My plan is to attach the board using the bosses as nuts. Get the board in final position and then mark location of the bosses. I'll epoxy them in place, mount the board to hold them in place. Then I'll add some epoxy between the boss and adjacent wall for good measure...
[ Invalid Attachment ]
[ Invalid Attachment ]
[ Invalid Attachment ]
[ Invalid Attachment ]
-
I like it! Keep us updated on your progress.
During some recent airhead work for a friend I installed a commercial LED taillight replacement which really lit up the running and brake illumination but I was a bit disappointed that there were no flashing options.
-
I like it! Keep us updated on your progress.
During some recent airhead work for a friend I installed a commercial LED taillight replacement which really lit up the running and brake illumination but I was a bit disappointed that there were no flashing options.
I know what you mean. I really liked having that strobe on my K100 to give extra visibility when at a stop light. If I was off the brake but see a car coming up from behind I'd squeeze the brake lever a time or two to make sure they're slowing down. Seems it would maybe catch someone's attention if their texting. There was someone that got killed at an off ramp last year not too far from my house. Driver was under the influence and didn't see the vehicles stopped at the light, I guess. Motorcyclist got caught between her and the pickup truck in front of him. Not sure a strobe would have made a difference in that case though.
-
Not sure a strobe would have made a difference in that case though.
Drivers regularly crash into lit up police cars parked on shoulders. In attempts to avert that, intermittently flashing, rather than pulsating, strobes have been developed. There's a body of evidence that suggests pulsating strobes can attract some drivers rather than alert them. It's a jungle out there. :laughing4-giggles:
-
Got the board mounted. Next step is to get it connected to the bike and test it out before I button it up.
[ Invalid Attachment ]
-
Drivers regularly crash into lit up police cars parked on shoulders. In attempts to avert that, intermittently flashing, rather than pulsating, strobes have been developed. There's a body of evidence that suggests pulsating strobes can attract some drivers rather than alert them. It's a jungle out there. :laughing4-giggles:
That's interesting, thanks for sharing! The strobe/flash pattern is selectable so I'll have to choose wisely. It's also good to just be aware of who's coming up behind you and leave an escape route.
-
Got the tail light wired up and did a comparison between my original (which used LED replacement bulbs) and the Custom LED version.
Day Time Comparison - the running light was barely noticeable...
https://youtu.be/uVAOx6uyKwM
And at night and a little further back...
https://youtu.be/wWX7RevQZ-s
-
Here are the things that can be adjusted...
1 - Start sequence that comes on when ignition is turned on can be turned on or off
2 - The brake alert pattern can be changed (see the 11 options early in the thread)
3 - The running light brightness can be adjusted within a preset range
4 - The brake light brightness can be adjusted within a preset range
I haven't played with the brake patterns yet... but I do want to change it to something else. The standard pattern is 4 quick strobes then solid. I find the 4 strobes to be too fast.
-
That's an excellent outcome! Thanks for a thorough presentation and video of this project. 112350
-
That's an excellent outcome! Thanks for a thorough presentation and video of this project. 112350
I've received and pulled so much helpful information from this forum that it just seems appropriate to give a little back.
The custom LED board cost me $441 but that includes the design work. I was told subsequent orders would cost less. I can't remember the number he gave me but seem to think it was around $140 or so.
-
Now that I know the electronics work, I went ahead and hot glued the red lens to the housing. Used a tooth pick to set a small gap between the red lens and the white housing to give the hot glue something to go into. It's about the size of the gap created by the Dremel so this should also get the overall size close to original.
[ Invalid Attachment ]
With the board spanning across the entire tail light, the ends are open to the environment. I know the tail light doesn't seal against the rear cowl so leaving it open is a bit of a concern. I don't drive in the wet if I can avoid it but sometimes you can't avoid it. I may play around with adding side walls.
[ Invalid Attachment ]
-
That's a big improvement! Make sure it can drain at the bottom if water could get in there. You could use a sealant or potting material to coat the PCB then it would be protected too. Makes repairs in the future a lot harder though. 112350
-
That's a big improvement! Make sure it can drain at the bottom if water could get in there. You could use a sealant or potting material to coat the PCB then it would be protected too. Makes repairs in the future a lot harder though. 112350
Good suggestion... I was thinking something similar, use something to fill in the ends. I'll look at what I can do. Thanks!
-
If you are planning to produce these in bulk, then I'd suggest looking into JLCPCB.com. They are a PCB manufacturer and they also do assembly work. They take your design and construct the board, then populate it with components you select from their parts supply house, LCSC.com. You pay by the size of the board but overall it is the cheapest option for you. Its the service I use for my electronic projects.
Now that you have a working prototype, you might want to consider moving from through-hole technology to surface mount technology. You'll open up a whole new world of design and manufacturer flexibility. Did the guy who designed the board for you give you the design files (or just the Gerbers)?
-
Now that you have a working prototype, you might want to consider moving from through-hole technology to surface mount technology. You'll open up a whole new world of design and manufacturer flexibility. Did the guy who designed the board for you give you the design files (or just the Gerbers)?
I got the board thru Custom LED who sells LED tail light assemblies for motorcycles. They designed the PCB mechanicals to my specs (board outline, mounting holes, wiring location) but it's their circuit design and their code. I reviewed their layout and made a few alterations. The board was delivered fully assembled and tested.
-
A side by side compare...
[ Invalid Attachment ]