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Hi   Instructables, in My First Instructable Project I was design a High Bright  Hunting Head Light using waste Torch Light With  4v rechargeable battery. The original Fore Head Light costs $6-$7, but these lights costs less than $ 2 and also makes recycle the torch.  I make this project similar with  ultra bright led emergency lamp by ASCAS


TOP USES:
1. Night Guide Light
2. Hunting Light
3. Search Light
 

Step 1: Gathering Tools & Materials

Materials:

-1W Ultra Bright LED
-Red LED Indicator(Here I am using white LED)
-Resistor (100-300 ohm)
-1N 4007 Rectifier Diode
-DC Power Jack (Female Port)
-4v Lead Acid Battery (Normal China Made Battery)
-Wire (Twisted)
-Old or Damaged Torch Light (China Made Torch Light)
-Elastic Belt
-Cloth Belt (Or Old Back Bags Adjusting Rope)
-Rivets (Available in Normal Stationary Shops)


TOOLS&EQUIPMENT:

-Soldering Iron
-Soldering Wire
-Hot Glue Gun
-Wire Cutters
-Hacksaw Blade
-Screw Driver
-Insulating Tape

Step 2: REMOVE THE WASTE PARTS FROM TORCH LIGHT

1. Remove the top and bottom parts of the Torch Light
2. Make small cut on both sides of neck of the Torch Light head

Step 3: INSERT THE ELASTIC BELT INTO TORCH LIGHT HEAD

1. Remove the clip on anyone side of the Elastic Belt.
2. Insert the Elastic Belt through the cut on torch Light Head.
3. Again place the clip using the Rivets

Step 4: STEP 4: MAKE THE SUPPORT USING CLOTH BELT

1. Connect the one end of Cloth Belt on back side of the Torch Light by using small Iron Piece.
2. Connect the other end of the Cloth Belt to Elastic Belt

Step 5: MAKE THE RECHARGEABLE LIGHT

1. Make Soldering as per this schematic diagram. For the switch we use the switch of the Torch Light.
2. Place the 1W LED on illuminating part of the torch light using the glue gun.
3. Place the   circuit on inside of the neck of the Torch.
4. Place the dc port on side of the torch light neck.
5. Place the Battery on clip of the Elastic Belt using long wire.
6. Place the indicating LED on anyone viewing side.
7.Gluing all the parts.

Step 6: CONNECT AND FINISH

1. Join the top and bottom side of the Torch Light using Glue Gun and Insulating Tape.
2. Finish the work and Charge the battery and use it.
3. Wear the light on head by adjusting two belts.
Press the button and Enjoy  yourself.

Step 7: WEAR LIKE THIS

Place the light on Head like this.

The power of this Light is similar to the ultra bright led emergency lamp by ASCAS

power of this light
 

<p>Hello dear,</p><p>This is Sherwin.</p><p>Very nice instructable, here some better instructions:</p><p>1. Use 4v 1aH battery for more backup.</p><p>2. To charge use branded NOKIA 5v 1a cellphone charger, because nokia is best in quality. </p><p>3. for charge indicator led(red) use any value between 220- 470r resistor, for white led use between 68-100r resistor.</p><p>4. Use resistor for 1w led ranging between 4r7 to 10r, using value above 10r may reduce brightness.</p><p>5. Use heat sink compound between led base and heat sink for better heat transfer.</p><p>6. Switch in diagram can get warm, use spdt slide switch (spst=2pin, spdt=3pin).</p><p>Good luck.</p>
Your idea is super. I make these changes and republish the instructable as soon as possible.I really thank you to show interest on my instructable.I welcome more ideas from you.
<p>To be friendly,</p><p>1. Use a 1w resistor for the 1w led. </p><p>2. Always ensure slow dimming for 1w led, just add a 1000uF 25v cap in parallel to it, this can increase lifetime.</p><p>3. Red led is best for charge indicator, forward voltage is 1.7-2.1v 10-20mA. Better value of resistance is 1k.</p><p>4. Always remember to charge battery after each use, this can maintain battery strength.</p><p>If you have any doubt, feel free to ask.</p>
Thank for your care sherwin,i have lot of modification in this instructable but I don't have money yet after I get money I make these changes. Thank you

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