Headlamp from scratch

yclo

Flashaholic*
Joined
Oct 8, 2001
Messages
2,267
Location
Melbourne, Australia
Headlamps, useful for hands free operation but has annoying strap that goes over your head. There are lights that attach to your ear but since I wear glasses, that seemed like the perfect place to secure it to.


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I have chosen to use a Cree XR-E which by itself gives a very nice flood without any kind of reflector or optics. It is driven at 400ma with dat2zip's wizard board, which allows for an input voltage between 3V~12V (or could be 16V? I forget the upper limit for the Vin of the old Wiz boards) giving a great deal of flexibility in battery configurations. A generic power supply plug is used on the end for easy changing between different power sources.


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The back of the headlight has two holes drilled and tapped for M3 screws, and a piece of kydex that has been shaped to fit on the side of my glasses is secured to it via button head screws.


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As some of you may have noticed, the wiring looks very similar to a typical handsfree kit for a mobile phone. Because I could not fit an on/off switch into the headlight itself, I figured it would be better to have the switch closer towards the headlight for easy access. I opened the handsfree casing, removed the microphone, fitted a slide switch inside and cut an opening on the casing so that the slide switch can be used. While I was at it, the original button was wired for momentary on.

(Canon 400D/rebel DSLR users, the handsfree kit for older Nokia mobile phones use the same 2.5mm plug as the wired shutter for the 400D/rebel. In the past when I had the Canon 300D, I did pretty much the same thing to a handsfree adding both a slide switch and a second momentary switch. When plugged into the 300D, one momentary switch toggled focus, the second momentary switch toggled the shutter, and the slide switch was used for bulb exposures.)


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The entire head assembly was machined from scratch, and also includes a mineral glass lens and 2 o-ring seals for keeping moisture out.



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A decorative reflector like the one used in my first light is used to keep pressure between the glass window/o-ring/bezel lip. Once the hole in the side where the wire goes in has been sealed with silicone, the headlight portion should be completely water proof.


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That's it!

-YC
 
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dat2zip's wizard board drives a Cree XR-E at 400ma, but due to the low mass of the light it gets really hot and even shuts off. I am unsure whether the temperature protection is built into the IC or the wizard board.

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-YC
 
Having seen this in action all I can say is I want one. :)
Very cool, very usable, much nicer than those ugly dorky plastic headlights.
Norm
 
The over temp if any is the IC shutting down when it gets around 120C. The IC package is very poor at moving the heat away to the surrounding air and needs assistance. Potting the converter board will help. The light might get a bit hotter and most likely not shut down if potted.

Good luck,

Wayne
 
This is COOL and INNOVATIVE !!!!
Very frakking cool !!!!
:bow: :thumbsup:

One of the best custom thingies I have seen in a long time ... :eek:oo:

bernie

P.S.: I need glasses ... :D ...
 
YC, post #2 in the link below might be of interest to you. :shrug: The MC-PET material Don mentions deffinately sounds interesting to me. :D My thought on this is by using this material you can decrease the drive current a little as well as potting the driver as Wayne mentioned to help with your over heating issue on this light without a noticeable difference in the lights output. I have no idea where you can buy this MC-PET material.

http://www.candlepowerforums.com/vb/showthread.php?t=167830

Ken
 
The external switch is the icing on the cake. :thumbsup:

Now ... think of a volume controler in addition to a simple on/off switch ... and you got something that a lot of people could actually use at work. A lot of people.

I really like this one !!! :D

bernie
 
:thumbsup: Now.... all I need are glasses. Hey, I could use clear unpowered ones. Hmmmm.... :)
 
Thanks guys, it was definitely fun to make and in time for field testing at the Melbourne CPF meet. I'm sure the guys at that meet can attest that it was quite good at illuminating my hands when I checked out their lights.

Flood is king for close up lighting.

Ken - That white stuff does sound very interesting indeed, but that means you'll have to give up on your carbon fiber!

Bernie - Volume controller is an excellent idea, I will keep an eye out for cheap headphones with volume knobs and see whether I can use it with a driver board.

It is still slightly heavy, when I wear the glasses pictured in the first post the side with the light gets pushed down slightly but not in an annoying way. If you don't wear glasses, I'm sure those clear len protective glasses are a good place to mount one or even just the frame with no lens.

-YC
 
That's awesome. That thing really looks professional. Nice touch with the corded switch so you don't have to fumble with the light itself.
 
I can very well imagine that light on a head strap like a traditional headlamp with a 1xCR123 tiny battery pack. That would make one awesome small and useful floody headlamp. :eek:oo:
I'd buy one in a second.
bernie
 
Fantastic light, I just saw this thread today and I want one immediately :D. You might back off the current from 400ma to something lower, to keep it cooler.
 
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