yea they do get a tad warm, that light was only run on 12 aa batteries though not a whopping big 12v car battery lol, never melted the plastic tho and they ran for a good hour before starting to lose power, i suppose they keep cool when your moving, so when on a car you can move faster than a mountain bike so should keep them very cool, failing that use alluminium as housing, you can get cheap alluminium torches, I bet the housing off one of them would do, also then you have the extra glass to cover the front already made and in place. I'm thinking of starting a project like this myself, we will have to compare notes on what we find best to use.