Inspired by mbouck's Biktrix thread, I decided to add a big headlight powered by the motor battery. I liked the look and price of 12v options intended for motorcycles, so I added a DC step-down converter to the plan. The headlight I chose has daytime running, low, high beams, so I threw in a handlebar switch. I swapped the resettable fuse for an ATM fuse, 'cause I want to break the circuit and be forced to take a look if there's a short. I upgraded to a 100v solid-state relay from a reputable manufacturer after toasting a few cheap 60v SSRs from Amazon. Mounting the headlight to the bars was tricky 'cause the bull bar mounts hit right at the taper / rise in the handlebars. I repurposed a strip of rubber that came with a Kryptonite lock mount to fill the gap. Here's the full build list:
- 5.75" LED Headlight with Housing
- 1.25" Light Bar Mount - connects the headlight to the handlebars
- 7/8" Handlebar On-Off-On Switch - for daytime running, low, and high beam. I wired it so DRL is on in all three modes.
- XT30 Connectors - To make the headlight, taillightI, and SSR easy to replace. I tried XT60 first but both the connector and the wires were too big to fit nicely above top battery mount.
- 48V to 12V 120W Step Down Converter - This is more than double the capacity I need, which should keep it relatively cool. It fit inside the spare space in the headlight housing.
- Panasonic AQZ105D SSR SPST-NO 2.3A 0-100V - Switches battery output using the low power light output wire from the Bafang Ultra controller. Easily fits in the down tube above the top battery mount.
- ATM Fuse Holder - I used a 3A fuse, between the battery and the SSR.
- 4.5" Adhesive LED Brake Light - Bright, minimal, and very affordable.