So I decided to do a HID flashlight. Well, it's sort of a flashlight, but highly modified.
I'm still waiting for all the parts, but I'm getting antsy, so I'm starting the thread early. I am waiting on the HID kit, but I'm going to work on the flashlight head here and add to this as it comes together.
Here's a list of the major components:
An automotive 35W HID kit, it's a full kit with 2 ballasts and 2 4300K H1 bulbs.
A Maglite 2D, that's the host for the bulb.
A 15A switch
A Power Sonic 12V 9A SLA Battery, (with a Power Sonic charger).
A Canvas Fanny pack
Wiring & fuseing.
Several photographic adapters and a 95mm Lens Hood with a 95mm Glass Filter.
A 95mm dia x ??mm deep Reflector, polished Aluminum.
Ok, what the heck is the idea here? Well, I wanted a 35W HID that I could carry easier than those big Spotlights, but I didn't want to spend $200-300 bucks on a handheld light and I wanted something to do with my time. So..... I am making a highly modified Maglite that holds the bulb and the igniter, with a fanny pack that holds the SLA battery and the Ballast.
Ya, I'm crazy (certifiable), but y'all should know that by now..... The guy using hand saws, files and sandpaper..........
So, here's the idea as I see it right now. The 12V battery will Just fit into the large pocket of the fanny pack. It weighs just under 6# and is approx 7" long, 2" wide and 3" tall. The ballast will be on the outside of the pack and it will go up against an insulated metal plate, from the inside.
The igniter is external from the ballast, so it will go inside the body of the Maglite. The bulb will fit in a holder that I make. It will be rigid in place, but the reflector and head will still rotate just as a Mag normally would, to make the reflector adjustable to the bulb. Hopefully that will allow for focusing of the beam.
The 15A switch will fit inside the normal Mag switch housing.
The head ends up being 95mm wide and about 125mm deep. It will house the reflector, which is an Aluminum polished reflector normally used for CFL bulbs.
The Wiring from the ballast to the ignitor will be lengthened, so that the Maglite can be easily carried like a normal flashlight, with freedom of movement and there will be a holder on the belt for the light, so it doesn't have to be hand carried all the time.
That's enough for now........... So what I can work on now is the head, to prepare it for the reflector. I have some photos of what I've done with the head and I will add stuff, as the rest of it comes in.
First off I used 3 different photographic adapters to get from 55mm (just about the same thread size as a Mag head) to 95mm (the size of the Lens Hood). I can't simply screw the adapter on, the threads are not the same, but the diameters are close enough to work with. I took the top cover off the head and cut it just past the front area that holds the lens "O" ring. You can see the black mark in the photo, that's where I cut it.
I smoothed it down and tapered it. Now it will screw back on the head Upside Down.
See the bottom of that cover is just about right to force over the 55mm threads on the photo adapter, so that's why I cut the cover and put it on Upside down, so I can use the other end to attach to the adapter.
This second photo shows what I mean from the black mark on it. That end will be the one fitting on the 55mm adapter.
Now this photo shows the Mag ring press fit onto the 55mm adapter. It was a "Press Fit" as in a large rubber mallet. It won't go anywhere and it still will thread back onto the Mag head. This photo also shows all three photographic adapters. Now it's ready to have the hood put on and go on to the head.
Here's the whole thing together. The "O" ring still works as a moisture barrier, just like it did originally. I have used a Black paint finish that I really like a lot. It gives a texture feel and it looks good too.
Here's the 95mm Filter, that will be the lens for the light.
and that's all I can do right now, I'm waiting for parts, so I will let it sit for now.
EDIT:
Well I forgot about the darned switch. I can show that stuff too....
I've basically gutted the stock switch, took off the tower and opened up the inside, to fit in a 15A rocker style switch. Here's the photos.
First is the rocker switch before and after......
Then, the stock switch gutted and opened up with files and paper.........
Then the rocker put into the modded Mag switch housing.......
Continued in Post #17.............
I'm still waiting for all the parts, but I'm getting antsy, so I'm starting the thread early. I am waiting on the HID kit, but I'm going to work on the flashlight head here and add to this as it comes together.
Here's a list of the major components:
An automotive 35W HID kit, it's a full kit with 2 ballasts and 2 4300K H1 bulbs.
A Maglite 2D, that's the host for the bulb.
A 15A switch
A Power Sonic 12V 9A SLA Battery, (with a Power Sonic charger).
A Canvas Fanny pack
Wiring & fuseing.
Several photographic adapters and a 95mm Lens Hood with a 95mm Glass Filter.
A 95mm dia x ??mm deep Reflector, polished Aluminum.
Ok, what the heck is the idea here? Well, I wanted a 35W HID that I could carry easier than those big Spotlights, but I didn't want to spend $200-300 bucks on a handheld light and I wanted something to do with my time. So..... I am making a highly modified Maglite that holds the bulb and the igniter, with a fanny pack that holds the SLA battery and the Ballast.
Ya, I'm crazy (certifiable), but y'all should know that by now..... The guy using hand saws, files and sandpaper..........
So, here's the idea as I see it right now. The 12V battery will Just fit into the large pocket of the fanny pack. It weighs just under 6# and is approx 7" long, 2" wide and 3" tall. The ballast will be on the outside of the pack and it will go up against an insulated metal plate, from the inside.
The igniter is external from the ballast, so it will go inside the body of the Maglite. The bulb will fit in a holder that I make. It will be rigid in place, but the reflector and head will still rotate just as a Mag normally would, to make the reflector adjustable to the bulb. Hopefully that will allow for focusing of the beam.
The 15A switch will fit inside the normal Mag switch housing.
The head ends up being 95mm wide and about 125mm deep. It will house the reflector, which is an Aluminum polished reflector normally used for CFL bulbs.
The Wiring from the ballast to the ignitor will be lengthened, so that the Maglite can be easily carried like a normal flashlight, with freedom of movement and there will be a holder on the belt for the light, so it doesn't have to be hand carried all the time.
That's enough for now........... So what I can work on now is the head, to prepare it for the reflector. I have some photos of what I've done with the head and I will add stuff, as the rest of it comes in.
First off I used 3 different photographic adapters to get from 55mm (just about the same thread size as a Mag head) to 95mm (the size of the Lens Hood). I can't simply screw the adapter on, the threads are not the same, but the diameters are close enough to work with. I took the top cover off the head and cut it just past the front area that holds the lens "O" ring. You can see the black mark in the photo, that's where I cut it.
I smoothed it down and tapered it. Now it will screw back on the head Upside Down.
See the bottom of that cover is just about right to force over the 55mm threads on the photo adapter, so that's why I cut the cover and put it on Upside down, so I can use the other end to attach to the adapter.
This second photo shows what I mean from the black mark on it. That end will be the one fitting on the 55mm adapter.
Now this photo shows the Mag ring press fit onto the 55mm adapter. It was a "Press Fit" as in a large rubber mallet. It won't go anywhere and it still will thread back onto the Mag head. This photo also shows all three photographic adapters. Now it's ready to have the hood put on and go on to the head.
Here's the whole thing together. The "O" ring still works as a moisture barrier, just like it did originally. I have used a Black paint finish that I really like a lot. It gives a texture feel and it looks good too.
Here's the 95mm Filter, that will be the lens for the light.
and that's all I can do right now, I'm waiting for parts, so I will let it sit for now.
EDIT:
Well I forgot about the darned switch. I can show that stuff too....
I've basically gutted the stock switch, took off the tower and opened up the inside, to fit in a 15A rocker style switch. Here's the photos.
First is the rocker switch before and after......
Then, the stock switch gutted and opened up with files and paper.........
Then the rocker put into the modded Mag switch housing.......
Continued in Post #17.............
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