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Thread: Build Thread - Custom Running Headlamp

  1. #1

    Default Build Thread - Custom Running Headlamp

    Hi All,

    Thought I'd share my headlamp after a recent comment to a Thread. I'll make it a quick read.

    Some background: I run quite a few Ultra trail marathons amongst all my other adventures so I'm constantly on the search for better gear etc. I basically started my crusade because I felt that no commercial headlamp ticks all the boxes for me and I decided to build my own.

    Requirements I had:
    • As small as physically possible
    • As bright a possible for the physical size
    • Long runtime at an "acceptable" level for running through an entire night, possibly multiple nights (Efficiency)
    • Flexible battery usage: I wanted the freedom to use any Li-Ion battery and any any number of the depending on my needs. (1x18650, 1x26650, 2x, 3x, etc.)
    • As weatherproof/waterproof as possible.


    After some some time on Ol'Google and a love-making session with my calculator I decided on the following parts:
    • 3xXP-L2 LEDs
    • Carclo 10507 optics T
    • Taskled L-flex driver
    • Wired battery pack(s)


    I tried to design the light body to provide as best cooling as possible, but knowing I won't be able to cool the light at it highest level...roughly 15W. Initially I was hoping to make it myself on the lathe at home, but I simply didn't have the time, so I opted to have it made by a engineering shop. There's a chap there that makes custom vapes so he was all to happy to take it on. Problem is I had to make 5 to justify the cost, so I decided to market it to friends (fellow Ultra runners) by giving it a personal touch.

    Anyways, a picture is worth a thousand words, so here we go:

    3D model of the body:
    [IMG]IMG_3698 by Eduan Adams, on Flickr[/IMG]
    [IMG]IMG_3699 by Eduan Adams, on Flickr[/IMG]

    First Cuts:
    [IMG]IMG_4264 by Eduan Adams, on Flickr[/IMG]

    After Anodising and tapping:
    [IMG]IMG_5468 by Eduan Adams, on Flickr[/IMG]

    Holes cut for wiring etc:
    [IMG]D1742571-A650-4E45-BF58-5476504EA939 by Eduan Adams, on Flickr[/IMG]
    [IMG]A2A023C1-D9C6-4B68-8F71-7408BB12D6C8 by Eduan Adams, on Flickr[/IMG]

    Parts going in:
    [IMG]2DEF40B5-5910-4FE0-B3DC-DFA122314045 by Eduan Adams, on Flickr[/IMG]

    And Done:
    [IMG]8EC79582-40B7-4335-8A90-18BA6B8D7C55 by Eduan Adams, on Flickr[/IMG]

    Personal touch for friend who bought one:
    [IMG]87508BBB-7FE2-411E-A439-595DA1D6D81E by Eduan Adams, on Flickr[/IMG]

    Size Comparison to an Olight HS2:
    [IMG]F869F807-6AAD-44D7-8F7D-E7D2FB127824 by Eduan Adams, on Flickr[/IMG]

    My setup I used for a 100 Miler. 1x 21700 battery I kept in my hydration pack, and I mounted the Light to back of my cap to safe 10 grams on the strap
    [IMG]IMG_6626 by Eduan Adams, on Flickr[/IMG]
    [IMG]1648179F-E935-4594-8FC7-988DAE217AA9 by Eduan Adams, on Flickr[/IMG]

    And last but not least, Beamshots, taken on a Cricket field (white wall in the distance is 120 meters away):

    Control:
    [IMG]P3063022 by Eduan Adams, on Flickr[/IMG]

    Level 1:
    [IMG]P3063023 by Eduan Adams, on Flickr[/IMG]

    Level 2:
    [IMG]P3063024 by Eduan Adams, on Flickr[/IMG]

    Level 3:
    [IMG]P3063025 by Eduan Adams, on Flickr[/IMG]

    Level 4:
    [IMG]P3063026 by Eduan Adams, on Flickr[/IMG]

    Level 5 (+/- 1500Lm):
    [IMG]P3063027 by Eduan Adams, on Flickr[/IMG]

    Hope you enjoy. Q & A welcome.

  2. #2
    peter yetman's Avatar
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    Default Re: Build Thread - Custom Running Headlamp

    That looks amazing, what a professional build.
    Show us what you did with the battery packs if you have time, please.
    Really jealous.
    P

  3. #3
    Flashaholic* wacbzz's Avatar
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    Default Re: Build Thread - Custom Running Headlamp

    Awesome job! Any of the five left over for sale?!

  4. #4

    Default Build Thread - Custom Running Headlamp

    Ok, so battery pack: I 3D printed a small casing for a single 21700 cell and hard wired it. I didn’t care much for looks as the battery is purely functional for me. Simply duct taped it to make it sweatproof. There’s not much more to it really. https://flic.kr/p/2fZHGkv
    Last edited by Rekkie; 05-22-2019 at 02:14 PM.

  5. #5

    Default Re: Build Thread - Custom Running Headlamp

    Quote Originally Posted by wacbzz View Post
    Awesome job! Any of the five left over for sale?!
    Only 1 left, but the face plate is slightly “stained” so I thought I’d keep it too “play” with different components/setups etc.

  6. #6
    Flashaholic* Derek Dean's Avatar
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    Default Re: Build Thread - Custom Running Headlamp

    Fantastic job, Eduan. Small, simple, elegant, and beautifully finished. I especially appreciated the running man graphic on the front, a very professional touch that just screams out to become the logo for your new custom headlamp business: )

    Thanks for taking the time to share your journey. Where there's a will, there's a way!

  7. #7

    Default Re: Build Thread - Custom Running Headlamp

    Thanks Derek. I was pleasantly surprised how well everything turned out. What started as a simple project for my own use quickly snowballed and turned into a decent headlamp.

    Yup, definitely holding on to the logo! 🙂

  8. #8
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    archimedes's Avatar
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    Default Re: Build Thread - Custom Running Headlamp

    Really enjoy seeing build threads like this. Very nice job.
    ... is the archimedes peak

  9. #9

    Default Re: Build Thread - Custom Running Headlamp

    Super cool.
    The brighter the light, the darker the shadow.

  10. #10

    Default Re: Build Thread - Custom Running Headlamp

    Excellent work! Looks like it was professionally made.
    Hello darkness my old friend,
    I've come to talk with you again...
    I liked neutral tints before they were cool.

  11. #11

    Default Re: Build Thread - Custom Running Headlamp

    You’re hired!

    When can you start?

    :-)

  12. #12

    Default Re: Build Thread - Custom Running Headlamp

    What kind of weight with various batteries + head gear?, also what max and min lumens/hours does it get?
    The brighter the light, the darker the shadow.

  13. #13

    Default Re: Build Thread - Custom Running Headlamp

    Quote Originally Posted by eh4 View Post
    What kind of weight with various batteries + head gear?, also what max and min lumens/hours does it get?
    Weight of the headlamp unit alone is about 50grams. The battery depends on what setup you use, as do runtime, as do lumens based on which current and UI the Lflex is set to.

    Currently set at 3500mah (Leds in parallel) and in UIBQ and multimode, so light output as follows:

    L1: ~27 Lumen
    L2: ~205 Lumen
    L3: ~391 Lumen
    L4: ~758 Lumen
    L5: ~1387 Lumen

    Values are theoretical(calculated) OTF.

  14. #14

    Default Re: Build Thread - Custom Running Headlamp

    Wow, man, why couldn't you have made more? I want one! :-)

  15. #15

    Default Build Thread - Custom Running Headlamp

    Difference in price/unit between 5&10 was so little that it didn’t warrant the need to machine more. Machine costs for making just one housing =~$100, 5=~$35 and 10=~$30, so opted for the 5. The bulk of the initial costs was in making the housing as I couldn’t machine it myself. Also didn’t want to make 10 and then sit with a handful of units I couldn’t sell.

    Wish I could afford the Pocket CNC then I could make them to order basically.
    Last edited by Rekkie; 06-28-2019 at 09:44 AM.

  16. #16

    Default Re: Build Thread - Custom Running Headlamp

    Very impressive, nice design and execution. Enjoyed your story.

  17. #17

    Default Re: Build Thread - Custom Running Headlamp

    Really cool. I think you did great. I love tiny headlamps!

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