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Thread: HID Project

  1. #1
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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 10:59 AM.

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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.

  3. #3
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    cool...beamshots please.

    what was the total cost on this?

  4. #4
    Senior Member Road Fan's Avatar
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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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    Quote Originally Posted by Road Fan View Post
    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 11:02 AM.
    Making a Pilom Triple LED Headlight ? I have parts available :)
    Bell R2 Conversion
    HID Project
    Dynohub R2 Project & Custom Helmet Lighting
    Aurora P7 Review

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    Quote Originally Posted by joshandlauri View Post
    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.
    Making a Pilom Triple LED Headlight ? I have parts available :)
    Bell R2 Conversion
    HID Project
    Dynohub R2 Project & Custom Helmet Lighting
    Aurora P7 Review

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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 11:03 AM.
    Making a Pilom Triple LED Headlight ? I have parts available :)
    Bell R2 Conversion
    HID Project
    Dynohub R2 Project & Custom Helmet Lighting
    Aurora P7 Review

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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 11:04 AM.
    Making a Pilom Triple LED Headlight ? I have parts available :)
    Bell R2 Conversion
    HID Project
    Dynohub R2 Project & Custom Helmet Lighting
    Aurora P7 Review

  9. #9
    rhm
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    Quote Originally Posted by Unknown Cyclist View Post
    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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    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 11:05 AM.
    Making a Pilom Triple LED Headlight ? I have parts available :)
    Bell R2 Conversion
    HID Project
    Dynohub R2 Project & Custom Helmet Lighting
    Aurora P7 Review

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