Electronics, Lighting, & Gadgets - Low budget rechargable headlight setup..

I made one of these a long time ago because I got sick of purchasing so many C cell batteries and only getting an hours worth of ride time out of em..

Heres what I did..

I got an old water bottle..

I went on Ebay for an old Cateye HL-500 (2 C cell headlight) $6.99 shipped
I bought this because I like the beam pattern..

Then I went to Radio Shack for a 7.2V R/C car 2000mAh ni-cd battery /charger combo
Model: 230-0322 $24.99 (http://www.radioshack.com/product/index.jsp?productId=2062121&cp=2032056&pg=1&searchSort=TRUE&f=Taxonomy%2FRSK%2F2032056&y=7&retainProdsInSession=1&categoryId=2032056&x=6&kw=7.2v&kwCatId=2032056&s=A-StorePrice-RSK&parentPage=search)

R/C car wiring harness w/crimp connectors
Model: 23-444 $4.99 (http://www.radioshack.com/product/index.jsp?productId=2062132&cp=2032056&pg=1&searchSort=TRUE&f=Taxonomy%2FRSK%2F2032056&y=7&retainProdsInSession=1&categoryId=2032056&x=6&kw=7.2v&kwCatId=2032056&s=A-StorePrice-RSK&parentPage=search)

7.2v 700 mAh bulb (sais 600mAh on site tho?) fits right in place of the factory bulb.
Model: KPR118 $1.39 (http://www.radioshack.com/product/index.jsp?productId=2062384&cp)

I had some misc 18 guage aug outdoor wiring/speaker wire..
I modded the internal housing of the headlight to run wiring back to a water bottle where the 7.2v r/c car battery is..

So for less than 40 buckswith this setup I get a solid 3+ hours worth of run time and its rechargable..
If I could find this style of bulb in a Xenon, I'd be set..


Heres some pictures.


Inside the headlight housing..
I have it wired so that the stock switch is used to actuate.
http://i4.photobucket.com/albums/y104/PentastarTurbo/KLEIN/internalwiringR.jpg

housing mounted on bars
http://i4.photobucket.com/albums/y104/PentastarTurbo/KLEIN/P1010572R.jpg

backside of housing showing whre the wiring exits the housing..
http://i4.photobucket.com/albums/y104/PentastarTurbo/KLEIN/P1010573R.jpg

Wiring passes through the drinking part of the water bottle to the battery (niterider style?)
http://i4.photobucket.com/albums/y104/PentastarTurbo/KLEIN/P1010583R.jpg

water tight..
http://i4.photobucket.com/albums/y104/PentastarTurbo/KLEIN/P1010584R.jpg

all finished..
http://i4.photobucket.com/albums/y104/PentastarTurbo/KLEIN/P1010574R.jpg

Light output.. (its not aimed directly at the camera, its just how it looks..
http://i4.photobucket.com/albums/y104/PentastarTurbo/KLEIN/lightoutputR.jpg

there ya have it, just thought I'd share.. :D

Looking good, nice neat job.

The only suggestion I can make would be to fit a fuse down near the battery, It's cheap insurance. It could live in the waterbottle along with one or two spare fuses.

I think you did a great job.

Looking good, nice neat job.

The only suggestion I can make would be to fit a fuse down near the battery, It's cheap insurance. It could live in the waterbottle along with one or two spare fuses.

Really no need for a fuse. I can't think of any commercial system that uses one.

By the way, I did the same long ago. I've replaced the head light with Niterider heads (Nitehawk makes some good ones too) that use MR-11 bulbs. Much more robust and the light is better. You can also go to much higher wattages. And replace the plastic connectors with Dean's Ultra Connectors. They handle more current and are more rugged. I also used speaker wire so that I know what pole of the battery I'm using. Just some slight improvements.

well, fuses aren't needed.. the bulb acts as the fuse..

as for the MR-11 bulbs, got any pictures?

I'd love to have something, say.. twice as bright as what I have now.
but with this bulb housing, It'll start getting that infant mushy head situation from the heat..

Can you buy just the heads?

well, fuses aren't needed.. the bulb acts as the fuse..

as for the MR-11 bulbs, got any pictures?

I'd love to have something, say.. twice as bright as what I have now.
but with this bulb housing, It'll start getting that infant mushy head situation from the heat..

Can you buy just the heads?

You can buy the heads from NiteHawk (http://www.nite-hawk.com/store/customer/home.php?cat=273) and the mounts from them too. I'd look for a NiteRider NR50 (http://www.branfordbike.com/cgi-bin/perlshop/perlshop.cgi?ACTION=push&thispage=lights/lights5.html&ORDER_ID=504997131#item1b) which comes with all the wiring or you can get the heads from Niterider (http://www.niterider.com/store_headlamps.shtml). Change the bulb to a 15 or higher wattage (BatterySpace has cheap bulbs) and off you go.

Here's some pictures

http://i144.photobucket.com/albums/r181/cyccommute/IMG_0176.jpg

http://i144.photobucket.com/albums/r181/cyccommute/IMG_0179.jpg

http://i144.photobucket.com/albums/r181/cyccommute/IMG_0106.jpg

http://i144.photobucket.com/albums/r181/cyccommute/IMG_0104.jpg

You can buy the heads from NiteHawk (http://www.nite-hawk.com/store/customer/home.php?cat=273) and the mounts from them too. I'd look for a NiteRider NR50 (http://www.branfordbike.com/cgi-bin/perlshop/perlshop.cgi?ACTION=push&thispage=lights/lights5.html&ORDER_ID=504997131#item1b) which comes with all the wiring or you can get the heads from Niterider (http://www.niterider.com/store_headlamps.shtml). Change the bulb to a 15 or higher wattage (BatterySpace has cheap bulbs) and off you go.

Here's some pictures

http://i144.photobucket.com/albums/r181/cyccommute/IMG_0176.jpg

http://i144.photobucket.com/albums/r181/cyccommute/IMG_0179.jpg

http://i144.photobucket.com/albums/r181/cyccommute/IMG_0106.jpg

http://i144.photobucket.com/albums/r181/cyccommute/IMG_0104.jpg


I like your mount bar. Where did you get that from? How much did it cost? Can I get a better image of the bar without the lighting on the bike? I'd like to see how the bike looks without the lighting on it for daytime nakeness.


Thanks.

I like your mount bar. Where did you get that from? How much did it cost? Can I get a better image of the bar without the lighting on the bike? I'd like to see how the bike looks without the lighting on it for daytime nakeness.


Thanks.

It's called a Sidetrak. They are still on the net here (http://www.sidetrak.com/Catalog/accessories.html). I modified mine with a 1" aluminum tube to hold the light better. Here's a picture of it off the bike

http://i144.photobucket.com/albums/r181/cyccommute/IMG_0761.jpg

http://i144.photobucket.com/albums/r181/cyccommute/IMG_0762.jpg

http://i144.photobucket.com/albums/r181/cyccommute/IMG_0765.jpg

http://i144.photobucket.com/albums/r181/cyccommute/IMG_0766.jpg