The riverside path in to Oxford from the south has recently been resurfaced making the journey by the Thames much more pleasant. To add to the excellent riding surface, there is a spectacular array of wildflowers to see as I ride along. I took the opportunity to grab a few photos…
Having unboxed and inspected the new lamp it is time to prepare it for fitting to Rose, my trusty Thorn touring bike. First, I used the old wiring harness from the original headlamp as a template to cut the new cable to size:
Next, I stripped away a few centimetres of the cable sheathing to expose the two inner conductors:
Because these two conductors will be close to the road surface at the centre of the wheel hub they will need protecting with some heatshrink tubing that is supplied with the new headlamp. I use an electric heat gun to do the shrinking. It is like a hairdryer… but much much hotter!
After cutting the heatshrink tubing to the correct length, make sure to use a suitable tool for holding the work while heat is applied. Remember, the air from the gun is very hot and it only takes a few seconds to complete the task.
Here is how it looks after shrinking down:
Once cooled, another piece of heatshrink tubing is applied at the point where the two conductors enter the cable sheathing.
Now the conductors are ready to have the crimp connectors fitted. It is easy to fit them with a small pair of long-nose pliers.
As you can see, the crimps each have two sets of tabs. One set of tabs is bent over the copper conductor to create the electrical connection. The second set of tabs wrap around the insulation to add mechanical strength to the connection.
Time to add more heatshrink tubing, this time to protect the crimp connectors from damage.
The electrical connections are now prepared. We can now fit the headlamp to the bike…
The new headlamp has been fitted. As you can see, I had to replace the mounting bracket as well as the headlamp.
The crimp connectors take their place on the hub generator ready to supply power when needed.
The cable runs up the front fork as before and is held securely in place to prevent it fouling the brakes.
Rose is now ready for the next commute although it looks like she could do with a bath (the riverside path that forms part of my commute has been quite muddy recently). You can also see the rechargeable headlamp on the top of the handlebar that provides extra lighting and some redundancy if one lighting system should fail (I also run two tail lamps for the same reason).
Poor Rose. Years of cycle commuting has taken its toll and her hub-powered headlamp has fallen to pieces.
I like the simplicity of packaging. It suggests that all the effort has gone in to designing the light, not the box it comes in.
The new headlamp is unveiled. What else has come with it?
That’s everything needed to complete the replacement. The extra coiled cable is for running to the rear of the bike to power a tail light. However, Rose has two large Cateye LED lamps powered by batteries that help keep us visible at night.
As you can see, the lamp supplied is the version with the 140cm cable which will need to be cut to length and prepared for fitting to the front fork. More on this in another post…
My local bike shop recently spent some time pampering Rose, my touring bike and while there, she was treated to a new cassette and chain. What I didn’t realise was that the middle ring on the chainset also needed replacing. How did Rose tell me this? Every time I put power down through the pedals, the chain would skip and make horrible noises. Ouch! Poor Rose…
So, out with the debit card and a bit of searching found me a replacement chain ring and the tools to fit it. Rose is a happy bike once more!
The image shows the old and new 36 tooth chains ring side by side…