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Old 02-04-09, 10:26 AM   #1
Unknown Cyclist
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HID Project

I recently bought HID unit and wondered if anyone else had one like it or any ideas for an enclosure.








Last edited by Unknown Cyclist; 02-21-09 at 11:59 AM.
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Old 02-05-09, 12:17 PM   #2
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The ballast has a web address on it: www.brightstar-hid.com.

Specs for the ballast are:

Voltage input DC 9V~16V
Normal Voltage Input 12.8 VDC
Normal Current Input 0.9A
Power Output 10 5%
Maximum Current Input 16.2A
Operation Power DC 65 12V
Operation Temperature -20C~80C
Storage Temperature -40C~105C
Efficiency over 85%

And as far as I can tell the bulb is a 12W MR-11 10 (35mm diameter).

Specs for the bulb are:
Operation Voltage DC 65V 12V
Wattage 10.5W 0.5W
Current Input 0.9A
Output (Luminance) 550lm
Color Temperature 6000K
Life Span(hrs) over 1000 hrs
With UV-cut shield YES

I've just carried out a runtime test using a 8 cell 3700 mAh sub-c nimh pack.

The HID sustained full brightness for exactly 2.5 hours and voltage at the battery started at 10.65V (under load) and the ballast shut off when the voltage dropped to between 8V and 8.5V (under load).

Light output seemed to be adequate and more floody than I expected.
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Old 02-05-09, 08:40 PM   #3
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cool...beamshots please.

what was the total cost on this?
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Old 02-08-09, 08:20 AM   #4
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Very cool!

You need to consider radiating excess heat in this design. The efficiency of an HID bulb is around 50% give or take, and the bulb input power (same as ballast output power) is in this case around 10 watts. So the waste heat generated in the bulb is 5 watts.

The problem isn't as severe as with a 5 watt LED because the heat transfer requirement is not as stringent, but I think it could still heat up and distort.

The electrical and temperature specs look automotive.
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Old 02-08-09, 09:05 AM   #5
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Very cool!

You need to consider radiating excess heat in this design. The efficiency of an HID bulb is around 50% give or take, and the bulb input power (same as ballast output power) is in this case around 10 watts. So the waste heat generated in the bulb is 5 watts.

The problem isn't as severe as with a 5 watt LED because the heat transfer requirement is not as stringent, but I think it could still heat up and distort.

The electrical and temperature specs look automotive.
Cheers for the info, I was already concerned about waste heat so when I did the run test I placed the HID in a plastic tube (piece of waste pipe) after 2.5 hours the tube hadn't melted, touching the bulb wasn't a good idea however.

Here are the main possiblities for an enclosure:

Spice jar with clear lid (just happens to be the right size).


D cell extension tube from Maglite copy.


Length of black waste pipe which is an exact fit on the ballast.


A trip to Maplin yielded:

Last edited by Unknown Cyclist; 02-21-09 at 12:02 PM.
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Old 02-10-09, 12:57 PM   #6
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cool...beamshots please.

what was the total cost on this?
Cost so far:

Ballast & HID bulb 31
Switch 1.99
6A Figure 8 cable 1.09
Deal Extreme Handlebar Mount (sku15342) $3.98

I was given the black silicon, black plastic pipe, spice jar and D cell extension tube.

The batteries I already have and originally cost about 20 each.
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Old 02-10-09, 01:03 PM   #7
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More items for the HID build.

Black heavy duty silicon:


Likely candidates for powering the HID:
NIMH 8 cell 3700 mAh 2 hrs 30 mins (continuous) runtime 515g
Lipo 3S 2200 mAh 1 hr 35 mins (continuous) runtime 176g


Doner handlebar bracket from DX:





Last edited by Unknown Cyclist; 02-21-09 at 12:03 PM.
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Old 02-12-09, 04:09 AM   #8
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I visited Plumbase to see if they have anything about the size of the HID ballast:



40mm polypipe straight coupler
40 mm polypipe socket plug
Syphon washer
= 2.68

Last edited by Unknown Cyclist; 02-21-09 at 12:04 PM.
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Old 02-12-09, 09:05 AM   #9
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Doner handlebar bracket from DX:
Now that looks like it has some potential! What is it made of? How flexible is it?
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Old 02-12-09, 11:29 AM   #10
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Mount bolted on & syphon washer siliconed in place:


Switch and cable out fitted in tailcap:


Assembled body:


Completed lamp:


Fitted to bars:



Last edited by Unknown Cyclist; 02-21-09 at 12:05 PM.
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