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Discussion Starter · #1 · (Edited)
After spending about the last 2 months planning and acquiring parts my helmet light is finally done.
The light is based on a "Husky" 3 watt LED flashlight(794-653).
I disassembled the thing removed the old emitter and added a copper slug to the bottom of the head unit.

I then drilled through the head unit so I could run wires through the bottom into the body. The hardest thing was figuring out how and where to split the battery body, I didn't end up taking much length off-maybe 1 1/2". I was afraid of having an issue with stuffing 10 lbs of stuff into a 5 lb bag. This happened on another light I was building.

I ended up putting in a "sleeve" in the body to join the 2 halves together. I used some heavy wall 1" tubing and bolted into it instead of using set screws.
I'm using a new bFlex instead of a 3023 driver. The original switch I was planning on using broke during assembly and I couldn't find a small enough switch to replace it, so I went with a small momentary switch from Radio Shack. I mounted it on a washer to keep it in place and then used a spacer between it and the switch cover in the back.


I used some Cateye light mounts, I found a link on another post. They're cheap but sturdy and look good.

I decided to use the stock reflector that came with the light but had to cut about 1/8" off the height. I used some Krylon Crystal Clear to 'sputter' the smooth lens and break up some of the "cloverleaf" pattern I get from this lens. I do have some Carclo lenses coming, Ill test them when I get them.
So far I like the light, but I need to get a few rides in.
I do need to clean up the light a bit, I wrapped it in electric tape to keep it from getting marred during building/assembly and it left a bunch of residue.
The light should be fairly waterproof, seals at all junctions, even an O-ring at the sleeve junction.
I'll post some beam shots in the next few days, but so far it's way brighter than my other helmet light(double Cree) so I'm pleased. It also doesn't heat up too quickly, I think I left enough material to dissipate the heat efficiently.
This should be a nice compliment to the "Cube" bar light I have which overpowers my double Cree helmet unit.

 

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Discussion Starter · #2 ·
Finally got a ride in and got to compare the light to my others.While the light provides tons of actual light I find it's not that usable. I find that the beam is not focused enough and has a slight cloverleaf still, I must adjust the optic or put in the new Carclo's I just got.
I am lacking any real 'punch' in the center of the beam, it makes for a nice handlebar light but so far not a good helmet light. Will work on optics
Here are some beam shots. Large tree is about 75 feet away.


 
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