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Electronics, Lighting, & Gadgets HRM, GPS, MP3, HID. Whether it's got an acronym or not, here's where you'll find discussions on all sorts of tools, toys and gadgets.

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Old 07-17-07, 10:19 PM   #1
Chris D.
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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

R/C car wiring harness w/crimp connectors
Model: 23-444 $4.99

7.2v 700 mAh bulb (sais 600mAh on site tho?) fits right in place of the factory bulb.
Model: KPR118 $1.39

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.


housing mounted on bars


backside of housing showing whre the wiring exits the housing..


Wiring passes through the drinking part of the water bottle to the battery (niterider style?)


water tight..


all finished..


Light output.. (its not aimed directly at the camera, its just how it looks..


there ya have it, just thought I'd share..
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Old 07-18-07, 03:34 AM   #2
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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.
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Old 07-18-07, 11:45 AM   #3
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I think you did a great job.
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Old 07-18-07, 12:39 PM   #4
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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.
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Old 07-18-07, 07:05 PM   #5
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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?
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Old 07-20-07, 08:54 AM   #6
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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 and the mounts from them too. I'd look for a NiteRider NR50 which comes with all the wiring or you can get the heads from Niterider. Change the bulb to a 15 or higher wattage (BatterySpace has cheap bulbs) and off you go.

Here's some pictures







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New! Pokin' around the Poconos A cold ride around Lake Erie
New! Dinosaurs in Colorado A mountain bike guide to the Purgatory Canyon dinosaur trackway
Solo Without Pie. The search for pie in the Midwest.
Picking the Scablands. Washington and Oregon, 2005. Pie and spiders on the Columbia River!
Days of Wineless Roads. Bed and Breakfasting along the KATY
Twisting Down the Alley. Misadventures in tornado alley.
An Good Ol' Fashion Appalachian Butt Whoopin'.
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Old 07-20-07, 08:52 PM   #7
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Originally Posted by cyccommute View Post
You can buy the heads from NiteHawk and the mounts from them too. I'd look for a NiteRider NR50 which comes with all the wiring or you can get the heads from Niterider. Change the bulb to a 15 or higher wattage (BatterySpace has cheap bulbs) and off you go.

Here's some pictures








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.
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Old 07-21-07, 09:14 AM   #8
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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. I modified mine with a 1" aluminum tube to hold the light better. Here's a picture of it off the bike







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New! Pokin' around the Poconos A cold ride around Lake Erie
New! Dinosaurs in Colorado A mountain bike guide to the Purgatory Canyon dinosaur trackway
Solo Without Pie. The search for pie in the Midwest.
Picking the Scablands. Washington and Oregon, 2005. Pie and spiders on the Columbia River!
Days of Wineless Roads. Bed and Breakfasting along the KATY
Twisting Down the Alley. Misadventures in tornado alley.
An Good Ol' Fashion Appalachian Butt Whoopin'.
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