Lightweight Helmet Light

[Geir68]

The idea was to design a helmet light that was light enough to keep both the light and the batteries permanently mounted on a spare helmet.
When going to have a ride in the dark, i simply choose the helmet with the light permanently attached.This will be in addition to a floody barmounted light, so I was looking for a spotty light to "look around the corners" when riding.
I recently converted a Sieg X1 mill to CNC, so this was my first light made on a mill. I have used a lathe before for making flashlights.
Let the machining start:

I made a drawing i Autocad, and manage to squeeze two Cree optics, two LED and a driver(bflex?) into a light of 24x49x50mm(not including the ribs). Wall thickness is 2mm with a 4mm bulkhead for the LEDs.
This picture show the backside of the light, and the one inch hole for the driver. All up weight of the aluminium parts is 53g.

Sorry for the crappy cellphone pictures(and the messy work bench), but this show the front of the light housing with a Cree Q5 for a testfit. The front with the two 3mm screws is designed to push the optics and the led against the bulkhead. This makes is possible to use arctic silver paste instead of glue to maximize heat transfer. Living in Norway makes cooling very easy.
The yellow thing in the background is the start of the battery pack.Two LiIon 18650 cells are soldered together waiting for the heatgun to shrink the plastic.

I am still waiting for Cutter to ship me som R2 Leds and drivers(arent we all), but I installed a Q5 and SSC P4 LED and switch to have a testride. I had to use a 0.6Ohm resistor to limit the current to 1A.
All up weight is 180g. The batteries and light was velcro'ed to the helmet and im really happy with the result. The extra weight on the helmet was quickly forgotten. I miss the option to adjust the vertcal angle of the light, so I will have to make an adjustable helmet mount.

Thank for looking.
Geir

 

[znomit]

Nice work!
I use long strips of velcro on the helmet, its curved so moving the light forward points it lower for the MTB and back is higher for the roadie.

 

[Offroad'Bent]

What an absolutely beautiful light!
With your R2s in there your power to weight ratio will be amazing.

 

[msxtr]

Very nice, but I would use MC-E leds...

Greetings - Saludos

msxtr

 

[Geir68]

Well, I have some MC-E on order too, so I could always try...but I'm afraid that the mass and surface area is to small to keep eight dies cool enough.

There are no optic yet that makes the MC-E throw well. Ledil Boom reflectors are the best spot I have seen pictures of, but there is still a lot of spill.

One cool white and one warm white MC-E, with Boom reflectors running parallel at 500mA from a single bflex might work:naughty:

Geir

 

[dom]

Nice job Geir
I'd love to have a CNC at home hooked up to Inventor and EdgeCam.

Cheers
Dom

 

[Geir68]

Thanks Dom.
Your minT has been one of the inspirations for doing the CNC conversion of the little X1 mill. Its fantastic to be able to mill non-square parts.

I have a more capable mill sitting on the bench now, awaiting steppers and drivers. Watching the X1 take off 1mm of alu in each pass at 100mm/min is like watching paint drying.

Geir

 

[Zero_Enigma]

Geir,

Whats the cost in materials and time to turn out one complete unit? Dood... I'm just screaming 'MAKE KITS NOW!!!'. That is elegant. Inquiring minds would love to know how the heat is on that dual Cree Q5 and also I would -LOVE- to see a dual MC-E in that unit. God.. I have to change my underpants now. Sexy smexy.

 

[dom]

Hi Geir
I haven't enough time to make my own machine plus i'm lucky to be able to use works machines whenever i want.

Just a pity there is too much work to do and not enough time for myself :-(

What will your newer machine be capable of doing? Much faster feed we hope ?

Have you a background in machining? Very good job if that is your first light.

Keep this thread going with your new projects -very interesting.

I hope to get going again next year.

Cheers
Dom