Electronics, Lighting, & Gadgets - A Christmas Story......
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Unknown Cyclist
01-01-09, 04:07 PM
Once upon a time I found some interesting batteries:
http://i37.photobucket.com/albums/e61/Unknown_Cyclist/sku_5035_1-1.jpg
Specs:
25500 Rechargeable Lithium Battery (3.6V 5000mAh)
25500 = 25 mm dia. x 50.0 mm long (about the same size as a 'C' cell).
Unknown Cyclist
01-01-09, 04:21 PM
Anyway, sometime later I found these beauties (on ebay).....
http://i37.photobucket.com/albums/e61/Unknown_Cyclist/IMG_2122.jpg
http://i37.photobucket.com/albums/e61/Unknown_Cyclist/IMG_2123.jpg
Specs:
2 x 'C' cells (3 volt)
Bulb, Halogen 2.4V - 0.85A = 2 Watts
Estimated Lumen output = several
And these (DX):
http://i37.photobucket.com/albums/e61/Unknown_Cyclist/IMG_2131.jpg
http://i37.photobucket.com/albums/e61/Unknown_Cyclist/IMG_2139.jpg
:)
Unknown Cyclist
01-01-09, 04:47 PM
A plan began to form so at this point, I enlisted the help of Jan, a Professional Aeronautical Inventor.......
Here are his photos of the conversion:
Disassembly...
http://i37.photobucket.com/albums/e61/Unknown_Cyclist/IMG_2125.jpg
New Parts......
http://i37.photobucket.com/albums/e61/Unknown_Cyclist/IMG_2131a.jpg
Unknown Cyclist
01-01-09, 05:18 PM
Original switch....
http://i37.photobucket.com/albums/e61/Unknown_Cyclist/Bell_03.jpg
Dual Switch after conversion.....
http://i37.photobucket.com/albums/e61/Unknown_Cyclist/Bell_27.jpg
Lens before conversion......
http://i37.photobucket.com/albums/e61/Unknown_Cyclist/Bell_01.jpg
Lens after conversion......
http://i37.photobucket.com/albums/e61/Unknown_Cyclist/Bell_25.jpg
Unknown Cyclist
01-01-09, 06:03 PM
As supplied - front view
http://i37.photobucket.com/albums/e61/Unknown_Cyclist/Bell_01-1.jpg
As supplied - side view
http://i37.photobucket.com/albums/e61/Unknown_Cyclist/Bell_02.jpg
As supplied - rear view
http://i37.photobucket.com/albums/e61/Unknown_Cyclist/Bell_03-1.jpg
As supplied - disassembled
http://i37.photobucket.com/albums/e61/Unknown_Cyclist/Bell_04.jpg
Kit of parts for the modification
http://i37.photobucket.com/albums/e61/Unknown_Cyclist/Bell_05.jpg
Battery terminals removed
http://i37.photobucket.com/albums/e61/Unknown_Cyclist/Bell_06.jpg
Rear switch removed
http://i37.photobucket.com/albums/e61/Unknown_Cyclist/Bell_07.jpg
Unwanted material removed from switch hole
http://i37.photobucket.com/albums/e61/Unknown_Cyclist/Bell_08.jpg
Battery terminals after removal of unwanted tabs
http://i37.photobucket.com/albums/e61/Unknown_Cyclist/Bell_09.jpg
Switches and tailcaps; Left - original, Right - modified
http://i37.photobucket.com/albums/e61/Unknown_Cyclist/Bell_10.jpg
Unknown Cyclist
01-01-09, 06:15 PM
Switches in Depron holder, how the modified tailcaps sit together
http://i37.photobucket.com/albums/e61/Unknown_Cyclist/Bell_11.jpg
Battery terminals reinstalled
http://i37.photobucket.com/albums/e61/Unknown_Cyclist/Bell_12.jpg
Tailcap inverted to remove some of the centre pip
http://i37.photobucket.com/albums/e61/Unknown_Cyclist/Bell_13.jpg
Tailcaps inserted and the switches pushed in with the help of a plastic or card sheet
http://i37.photobucket.com/albums/e61/Unknown_Cyclist/Bell_14.jpg
Switches in position, a small piece of plasticard added to ensure they don't move when pushed
http://i37.photobucket.com/albums/e61/Unknown_Cyclist/Bell_15.jpg
Optics with Cree stars in place, small piece of card to keep them pushed outwards (removed once bonded)
http://i37.photobucket.com/albums/e61/Unknown_Cyclist/Bell_16.jpg
Aluminium block clamped to the stars after applying thermal epoxy
http://i37.photobucket.com/albums/e61/Unknown_Cyclist/Bell_17.jpg
The lamp cluster - front
http://i37.photobucket.com/albums/e61/Unknown_Cyclist/Bell_18.jpg
The lamp cluster - top
http://i37.photobucket.com/albums/e61/Unknown_Cyclist/Bell_19.jpg
Slots cut in top of rear bulkhead and bottom of battery guide for wires
http://i37.photobucket.com/albums/e61/Unknown_Cyclist/Bell_20.jpg
Unknown Cyclist
01-01-09, 06:20 PM
Wires soldered to stars
http://i37.photobucket.com/albums/e61/Unknown_Cyclist/Bell_21.jpg
LEDs fitted and wired up
http://i37.photobucket.com/albums/e61/Unknown_Cyclist/Bell_22.jpg
Material to be removed to ensure the batteries fit properly
http://i37.photobucket.com/albums/e61/Unknown_Cyclist/Bell_23.jpg
Batteries in place
http://i37.photobucket.com/albums/e61/Unknown_Cyclist/Bell_24.jpg
Finished light - front view
http://i37.photobucket.com/albums/e61/Unknown_Cyclist/Bell_25-1.jpg
Finished light - side view
http://i37.photobucket.com/albums/e61/Unknown_Cyclist/Bell_26.jpg
Finished light - rear view
http://i37.photobucket.com/albums/e61/Unknown_Cyclist/Bell_27-1.jpg
Unknown Cyclist
01-01-09, 06:29 PM
And finally.....
Some beamshots at 5m (4s exposure at f8 with ISO200):
Original light at 5m - 4s exposure at f8 with ISO200
http://i37.photobucket.com/albums/e61/Unknown_Cyclist/Bell_28.jpg
Modified light, 1 LED on, at 5m - 4s exposure at f8 with ISO200
http://i37.photobucket.com/albums/e61/Unknown_Cyclist/Bell_29.jpg
Modified light, 2 LEDs on, at 5m - 4s exposure at f8 with ISO200
http://i37.photobucket.com/albums/e61/Unknown_Cyclist/Bell_30.jpg
Same again...this time with the lights shining into some nearby woods.......
Original light into the woods - 8s exposure at f8 with ISO200
http://i37.photobucket.com/albums/e61/Unknown_Cyclist/Bell_31.jpg
Modified light into the woods, 1 LED on - 8s exposure at f8 with ISO200
http://i37.photobucket.com/albums/e61/Unknown_Cyclist/Bell_32.jpg
Modified light into the woods, 2 LEDs on - 8s exposure at f8 with ISO200
http://i37.photobucket.com/albums/e61/Unknown_Cyclist/Bell_33.jpg
joshandlauri
01-01-09, 08:12 PM
awesome all around, super compact!
are the leds direct drive, no driver/regulator, direct battery to led?
also how are you charging these?
illdoittomorrow
01-01-09, 08:20 PM
Awesome :)
I've been considering doing something similar with an old Vetta 2C halogen light, but I'm worried about heat output (the fact that I know nothing about electronics is at the back of my mind, too :D). How warm does your light get, and which LEDs specifically are you using?
Unknown Cyclist
01-02-09, 07:07 AM
awesome all around, super compact!
are the leds direct drive, no driver/regulator, direct battery to led?
also how are you charging these?
Yes, LEDs (Cree R2) are direct drive.
Both LED, battery & switch circuits are completely independent.
Details of charger and runtime tests to follow shortly......
:thumb:
Unknown Cyclist
01-02-09, 01:15 PM
Awesome :)
I've been considering doing something similar with an old Vetta 2C halogen light, but I'm worried about heat output (the fact that I know nothing about electronics is at the back of my mind, too :D). How warm does your light get, and which LEDs specifically are you using?
Hi,
The LEDs are mounted with thermal epoxy to the aluminium heatsink.
The LEDs are Cree R2s.
Just doing some run tests and checking the temperature atm.
:)