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Old 01-01-09, 04:07 PM   #1
Unknown Cyclist
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A Christmas Story......

Once upon a time I found some interesting batteries:



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).

Last edited by Unknown Cyclist; 02-21-09 at 12:14 PM.
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Old 01-01-09, 04:21 PM   #2
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Anyway, sometime later I found these beauties (on ebay).....





Specs:

2 x 'C' cells (3 volt)

Bulb, Halogen 2.4V - 0.85A = 2 Watts

Estimated Lumen output = several

And these (DX):






Last edited by Unknown Cyclist; 02-21-09 at 12:16 PM.
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Old 01-01-09, 04:47 PM   #3
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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...



New Parts......


Last edited by Unknown Cyclist; 02-21-09 at 12:18 PM.
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Old 01-01-09, 05:18 PM   #4
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Original switch....



Dual Switch after conversion.....



Lens before conversion......



Lens after conversion......


Last edited by Unknown Cyclist; 02-21-09 at 01:01 PM.
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Old 01-01-09, 06:03 PM   #5
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Build Thread

As supplied - front view



As supplied - side view



As supplied - rear view



As supplied - disassembled



Kit of parts for the modification



Battery terminals removed



Rear switch removed



Unwanted material removed from switch hole



Battery terminals after removal of unwanted tabs



Switches and tailcaps; Left - original, Right - modified


Last edited by Unknown Cyclist; 02-21-09 at 01:03 PM.
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Old 01-01-09, 06:15 PM   #6
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Switches in Depron holder, how the modified tailcaps sit together



Battery terminals reinstalled



Tailcap inverted to remove some of the centre pip



Tailcaps inserted and the switches pushed in with the help of a plastic or card sheet



Switches in position, a small piece of plasticard added to ensure they don't move when pushed



Optics with Cree stars in place, small piece of card to keep them pushed outwards (removed once bonded)



Aluminium block clamped to the stars after applying thermal epoxy



The lamp cluster - front



The lamp cluster - top



Slots cut in top of rear bulkhead and bottom of battery guide for wires


Last edited by Unknown Cyclist; 02-21-09 at 01:24 PM.
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Old 01-01-09, 06:20 PM   #7
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Wires soldered to stars



LEDs fitted and wired up



Material to be removed to ensure the batteries fit properly



Batteries in place



Finished light - front view



Finished light - side view



Finished light - rear view


Last edited by Unknown Cyclist; 02-21-09 at 01:26 PM.
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Old 01-01-09, 06:29 PM   #8
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And finally.....

Some beamshots at 5m (4s exposure at f8 with ISO200):

Original light at 5m - 4s exposure at f8 with ISO200



Modified light, 1 LED on, at 5m - 4s exposure at f8 with ISO200



Modified light, 2 LEDs on, at 5m - 4s exposure at f8 with ISO200



Same again...this time with the lights shining into some nearby woods.......

Original light into the woods - 8s exposure at f8 with ISO200



Modified light into the woods, 1 LED on - 8s exposure at f8 with ISO200



Modified light into the woods, 2 LEDs on - 8s exposure at f8 with ISO200


Last edited by Unknown Cyclist; 02-21-09 at 01:39 PM.
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Old 01-01-09, 08:12 PM   #9
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awesome all around, super compact!

are the leds direct drive, no driver/regulator, direct battery to led?

also how are you charging these?
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Old 01-01-09, 08:20 PM   #10
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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 ). How warm does your light get, and which LEDs specifically are you using?
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Old 01-02-09, 07:07 AM   #11
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Quote:
Originally Posted by joshandlauri View Post
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......

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Old 01-02-09, 01:15 PM   #12
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Quote:
Originally Posted by illdoittomorrow View Post
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 ). 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.

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