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  1. #1
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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 11:14 AM.

  2. #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 11:16 AM.

  3. #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 11:18 AM.

  4. #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 12:01 PM.

  5. #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 12:03 PM.

  6. #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 12:24 PM.

  7. #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 12:26 PM.

  8. #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 12:39 PM.

  9. #9
    Got another new bike
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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?

  10. #10
    Beer and nachos today!
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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?

  11. #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......


  12. #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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