The (strong) newbie headlamp project

[TTT]

I have a Petzl Duo 5 headlamp that does not work properly anymore.

The goal is to create a headlamp as powerful as possible for the smallest amount of cash possible. oh yeah, it should also be simple to make.

I plan on removing the current lightsources and use the rest as a starting point for jamming in as many high-powered leds as possible.

The thing is, I currently live in Germany and my headlamp is in Norway, so I have not got the specs (size) of the housing precisely. If anybody knows them, it would be very nice to know!

Anyway, this does not stop me from planning. Ideally, I would like to stick with the 4xAA NIMH batteries. I could also use the lithium version (14500?) to ramp up the voltage if needed, but this means I need an extra charger and extra batteries are difficult to get hold of.

Can 4xAA batteries handle 2xP7 emitters? How many Q5s could they handle?

I would love to be able to keep things as simple as possible, and it would be great to be able to glue say 2 or 3 R2 drop-ins to the lensglass and just connect the wires:

http://www.dealextreme.com/details.dx/sku.11836

I think I should be able to fit 3 in it, as far as I remember the size. At least two.

Another alternative is fitting a 3 or 4xQ5 reflector, but this seems more complicated (have to get wire, get some heatsinking etc)

As this light is waterproof and made of plastic I am a bit worried about conducting heat away from the LEDS. With some sort of heatsink/buffer inside the housing, I think one could run the light for quite some time without too much heat. I hardly ever use it above 15 degrees celsius anyway.

Here is the original.

http://en.petzl.com/petzl/LampesProduits?Produit=270

Any input much appreciated! If I find a promising solution I promise to document my work with beamshots and more

 

[TTT]

Removed the electronics from the headlamp today. Measured that there should be room enough for two R2 drop ins.

Measured a depth of approx. 27 mm, + 5 mm lens clearance so I should have about 32 mm to work with. The unit should be 29 mm without the springs, which means it should just fit. Probably won't though

How "liquid" is thermal grease? Are there any other ways of improving heatsinking?

I am thinking of gluing the R2 drop ins to the lensglass (made of plastic) with epoxy. Is this a good idea?

I would also like to fill the spare room with some sort of heat buffer/heat sink. What can I use for this?

Btw, pictures are coming soon

 

[TTT]

How much will 4xNIMH AA sag under load of 8 watts?

 

[ifor powell]

If you end up with the modules fully enclosed then the heat is going to be a big issue, they look to be just on or off fully. Enclosed in plastic they are going to get too hot to touch after only a minute or two I don't know how long to melt the plastic but they may get there. As for the batteries you are probobly looking at 1.5A so they will sag, how mush will depend upon the how good they are. A bit af sag may be good from a heat point of view though.

Ifor

 

[TTT]

Well, I have looked at an alternate option:

Using the current lamp as a base for mounting two Romisen RC-T5 4xCree flashlight heads and using an external powersource, i.e. battery in pocket.

Should produce a lot of lumens!

anyway, i am getting my P7 light from DX and I am going to see how this might fit first.

 

[yo6ial]

This starts to become interesting...
I'm itching to see the results, as my "best" headlight mod consists in only one SSC P4, an d three warm-white 5mm's (finally : )
But be sure, about how much light you'll get! I didn't believe it aether, but there is possible to get "too much light" out from the headlamp.
"out there" things could get annoying, if the light would not be dimmable, or at least able to switch between a number of led's

 

[TTT]

I am now looking at a fourth option, which I think might be the most promising:

Machining 4x short tubes of alu (with about that of C-cells, 26,5 mm) and fitting 4x R2 Cree drop ins, and run these with my already existing 5-cell NIMH pack for my Silva LX. This should produce at least 600 lumen, probably about 800 "advertising" lumen.

Made a very quick and crappy drawing to illustrate:

Might need some hinges so that angle could be regulated.

 

[ifor powell]

With the 4 * 1 layout you will probobly want to have the holders pointing outwards a bit otherwise I would think it would be too big and flat along the front of your head. It will give you an oval which is good for Night Orientearing which I use my 3*2 layout for. If you don't want the oval effect the 2*2 will be better for a tighter throw with less flood.

Ifor

 

[clg0159]

I think it would be cool (and more useful) if you diffuse two of them so you have both flood and throw.