Introduction: Easy Super Bright Flashlight (10 Watt)

I wanted to build an easy flash light that last long and super bright. 

This is what i came up with.

I found the bulb on Ebay for about $20 and found out it's operating volts are about 3.6V-4.2V and 3 rechargeable batteries are rated @ 1.2 V each but normally they run at about 1.33x3 which is about 4 V even. so rechargeables are the way to go. I didn't use a driver for this  because the volts were in range. It works good for me and doesn't get hot. Ill see if it burns out or anything in the future. This does work with 3 AA's but I wanted one that would last longer so I went with 3 D's.

Step 1: Materials



Here is a list of materials used:

New SSC P7 White 900 Lumens 10W Light LED DIY 3.6V-4.2V (ebay $20)
Rechargeable D batteries (6 for $20 on Ebay)
Used flashlight that uses a regular bulb and 3 D batteries. Free. 

Tools:
solder and solder gun 
J-B weld 
little weights to hold it together
Duct tape to hold it together


Step 2: Assembly

1.) First thing to do is take the light apart and look at the reflective cup that the light bulb sticks out. This is where the led is going to stick out of. 

2.) The first problem I had was that there was a screw on light bulb holder that was connected to the negitive disk. So i cut it off from the reflective cup. 

3.) once that was cleared, I soldered the positive tip to the yellow wire and slipped it through the side of the little black plastic piece. and glued it to the negative disk. 

4.) Also I made sure that I made a notch so the wire doesn't get hooked on the negative connector. 

5.) Once I got that together I soldered a wire from the negative disk to the negative sign on the LED and the yellow wire to the LED.

6.) wait a few minutes for the LED to cool down from the solder and glue the led to the negative disk and finally to the Reflective Disk.  

A good thing is to make sure that the disk and LED are in the center. Mine was a little off and it's noticeable when turning the cover on the flashlight. It gets stuck on the negative piece that touches the negative disk. 

Step 3: Final - Testing

Check it out.. It's bright and it's powered by 3 D batteries so it should last...

This is a blinding light and shouldn't be looked at directly.

Good for remote projects that require a lot of light but no power sources.

Comments

author
jules15 made it!(author)2013-03-26

i could be wrong but isnt that a 3watt star? i have a ten watt and it uses 12volts.. and its SUPER bright lol. nice project

author
snowluck2345 made it!(author)2011-09-24

If your driving it at 10 watts its going to have a very short lifespan. I have an mce aswell as a p7 and both of those get VERY hot even with minimal heatsinking.

author
-max- made it!(author)2011-07-19

you need a better focus the led. the beam pateren looks terrible.

author
watch81 made it!(author)2011-07-22

haha yeah i know.. i was thinkin of doing something else with the led.. still donno what yet

author
-max- made it!(author)2011-07-22

modify a higher quality flashlight. also, a t6 led is better. i bought one, they are super bright (1000 lumens) and less than 5mm square

author
Scott_Tx made it!(author)2010-08-10

Its not going to last long without a bigass heatsink attached to it

author
watch81 made it!(author)2010-08-11

It didn't get hot on me yet. This was more of a test and see type of deal. So far so good. :)

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