Following on from the decent road bike light thread, I thought I'd share the results of my recent tinkering. I converted my old halogens last year but as my commute now involves several miles of unlit country road I decided some upgrades were in order, and in particular I wanted a remote on one of the lights.
I decided to switch to the bflex driver. This is even more of a squeeze than the black cat driver, but can be made to fit if you remove the switch and bend the connectors on the back of the power socket. The bflex driver has a pad on it for heatsinking. I made a small cube of aluminium and used some thermal transfer adhesive to attach the PCB to the cube, and the cube to the heatsink:
As well as giving the driver some heatsinking, it means that the driver's thermal cut-out detection should accurately detect the LED temperature.
For the remote, I wanted something discrete and easy to access. My 105 levers are Flightdeck compatible, meaning they have a little nipple on the inside of the hood that's designed to operate a switch. The real Flightdeck hardware is stupidly expensive, but I managed to bodge a miniature switch into the flight deck blanking panel so that it sits exactly behind the nipple.
The wiring and the socket are hidden under the handle bar tape.
The end result works very nicely. I'm running the bflex driver at 1000mA, and use the switch to toggle between "L1" (out of 5) and full power.
With the thermal cut-off set to 70 degrees, it'll run for a few minutes stationary indoors before cutting in, at which point the case is at 50 degrees. In real use, I've never had it cut in, and the case barely gets above luke warm.
The other light is running at 870mA with a mid optic, and pointed well down. The bflex light is pretty much horizontal with a spot optic. The "dipped" light is enough to cycle by, but it's not exactly relaxing. Both together gives loads of light well into the distance and means you can really relax, even at well over 20mph.
With the bflex light on minimum, the combination doesn't seem to cause any offence to oncoming drivers, but on full it's bright enough that drivers can see you coming round the next corner and dip their lights before they even see you.