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Discussion Starter · #1 · (Edited)
I starting to look at purchasing a torch for use as a headlamp for general firetail use. But after hearing some of the reports about manufacturers whos output figures you can't Trust and Dealers that lack service in the Extreme. I thought why not give a simple diy a spin and see how far $50 would go.:D
What I came up with is a fixed 1000ma buckpuck adhered to a switched 4aa holder. Where I can select internal or external power souce for the longer rides. ( via the center off switch)
The lighthead is a Cree R2 with an 8 degree optic. The helmet mount doubles as the heatsink and is held in place by a hair tie.

Pros: Cheap!
Light
Good power output
Long runtime off 4aa's
External power option
Low profile
Easy fitting
Simple to make
Battery weight at rear of helmet

Cons: Durability? (refer to first point of pros ;) )
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I see another Easy DIY platform in the making.

What are you using for stock for the light housing? Is it a manufactured cup or a tube with a cap you installed? Care to do a full build list with suppliers and part #'s?
 

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Discussion Starter · #4 ·
Hi, The housing tube is just some 22mm od tubing that I have AA'd a 3mm disc into for better heat transfer into the tubing. The front inner edge of the housing had to be chamfered to allow for mounting the optic housing, which also needed a flat filed on it as it is slightly larger than the tubing. The tubing is then AA'd and rivited to a 65 mm length of 25 x 3mm angle that has been cut to shape.
The optic itself is a cree 8deg. I went with the old 8deg as it gives a bit more spill than the new one. Though I may swap it over if I find I need a bit more spot when using bar lights as well.
I did look at making a twin emitter light but I didn't want to lose the battery on the helmet, or have to worry about heatsing and housing a boost driver. The buckpuck is simply epoxyed to the rear of the battery compartment with the wires routed through a couple of holes.
I've found tthat sitting on the table for 10mins the light does get quite warm, but cools quickly once moving. If the heat becomes a concern I'll just add one of these to the rear
http://www.jaycar.com.au/productVie...&pageNumber=&priceMin=&priceMax=&SUBCATID=751

The led kit is available here http://www.cutter.com.au/proddetail.php?prod=cut731

The battery housing here http://www.jaycar.com.au/productVie...&pageNumber=&priceMin=&priceMax=&SUBCATID=522

I had to remove the suppied slider switch and replace it with this one to give me the option of external power http://www.jaycar.com.au/productVie...&pageNumber=&priceMin=&priceMax=&SUBCATID=448

The power socket is here http://www.jaycar.com.au/productVie...&pageNumber=&priceMin=&priceMax=&SUBCATID=651

I hope it's inspired some more DIY! ;)
 
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