NICKSUCH.NET
October 2, 2009 | "Seek first to understand, then to be understood." - Stephen R. Covey
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recent post on kymba.org:
For <$50 and some internet research, I was able to make a commute/helmet mount headlight. I currently have a 20W, but am working on a couple 10W versions, so I'll describe those.1. 10W MR16 halogen bulb+reflector: harringtonlights.com,, ~$5
2. 12V battery pack, NiMH AA Cells, ~2000mAh, custom-made by BatteriesPlus (stores in Lou, Lex, all around) or check internet ~$25
3. Pair of Tamiya connectors, ~$2
4. 12V, 200mA Battery charger with Tamiya connector, ~ $6
5. Wire, inline fuse, lighted switch, electrical tape, velcro, zip ties, solder, empty pop bottle, gorilla glue, shipping on other parts: ~$11.99.
Total=$49.99 (Thought we'd cut it as close as possible).
I'm hoping to have a tutorial on my website soon, but classes are taking precedence right now. Cut pop bottle off at top of label (on the cap side, where the cylindrical portion meets the curve). Glue MR16 bulb/reflector to the inside of bottle section. Run about 3 feet of wire to the light. Poke hole in cap; run wire through it and solder to leads. Solder Tamiya connectors to battery terminals and end of light bulb leads. Find a good place for the inline fuse and switch. Tape (and heatshrink tube, if you have it) all the connections. Use velcro creatively to mount battery to bike, or place battery in camelpak/backpack. Zip ties fit nicely into the neck rim near the cap of pop bottle. Use this feature to mount to helmet. Charge battery and enjoy.
Sorry for lack of detail, hope to have more on http://www.nicksuch.net soon. This is about the cheapest way to make a great light. If you overvolt by 20% (14.4V battery), this setup nears the efficiency (lumens/watt) of HID. This setup should get you about 2 hours of burn time. Contact me if you have any questions. Also, check out http://bicyclelighting.com, from where I learned most of this.
-Nick
The aforementioned tutorial should be coming soon. Along with lights for Kevin, Brad, and whoever else I promised them to.
(From bicyclelighting.com: "Last Update: 25 March 2005". This was one of the best days of my life: My 19th birthday, the day Stephanie said "yes", and Good Friday.)