Step 5: Wiring it Up

Wiring on a flashlight is pretty basic. A complete circuit is just Battery Positive to Switch to Bulb and back to Battery Negative.

Since this is a rechargeable battery, it would be nice to also add a way to recharge the lantern without taking it apart to access the battery. To do that, we'll reuse the power cord port as a place to connect the charger to.

First, check to make sure the wires on the switch and power inlet will reach the battery and the bulb.

The "115/230" power switch won't be used, so its red wires can be snipped-off. Save them for reuse. It's good heavy wire, and red is typically used to indicate Positive polarity.

Strip and twist together one wire from each of the power switch and the power inlet. Add a female spade terminal and crimp it on. This connector goes to the Positive terminal of the battery. The other wire of the switch goes to the  bulb. 

The OTHER wire of the power inlet goes to the opposite side of the bulb. That side of the bulb also goes to the battery negative. This bulb has "multi-terminals" on it, so it's easy to connect two wires at once to a terminal - one with a spade connector, and one with a bare wire tightened down under a screw.

Once you are done, power will only go to the bulb when the switch is on, but power will always be connected to two of the pins of the power inlet. (Cut off the third wire.) That way a battery charger can be connected to the two pins to recharge the battery. Mark the two pins with the correct polarity.

(A note on reusing the switch: Switches and other components often have 2 sets of ratings - one for AC and one for DC. The ratings are typically much LOWER for DC. Use a flashlight to look closely on the side of the switch, and you will see its power rating. Because this is only a 1 Amp project, this switch will work fine.)

<p>You should replace the bulb with a COB LED, you can buy them for really cheap on eBay...</p>
You left the 220/115v plug and used it to charge the battery. It is a safety problem - someone can plug through it the battery to the 220/115 volt and blow the battery! Please destroy the plug or make it unusual.
<p>Things like that are fine when it&rsquo;s only the creator using it. If it was going to be mass produced and sold, obviously you&rsquo;d want to change that.</p>
Hey congratulations on being a finalist in the hack it contest! Good luck to you!
As a precaution, you should be careful when taking apart comp. power supplies! They still have power in them. A guy in my area (KC) was electrocuted from taking apart his power supply. Just a heads up!
Dont touch the Capacitors and you usually get away with it fine :) <br>
With a big(ish) battery like that, surely you could put a car headlight lamp in. I'm sure that would be bright enough for any possible need.
Sealed-beam car headlamps are commonly 55 watts. The landscape light is 11 watts.<br>The battery could run a car lamp for 1 hour or the lamp I used for 5 hours. It's more than bright enough for my needs, but yes, a person could use a headlight if they wanted to.
Appropriate idea :) cool .. you saved amount of casing .. and 1suggestion- Plz find out option of charging .. put charging adapter inside the lamp and connect that with the female shocket(which is already along with the case) then you'll need only power cable to plug in and charge .. it's easy and SAFE .. (in your recent design..if by mistake beginners attached power cable like computer .. your battery will blast :( .. )
It would be better if you had installed the charger inside the flashlight. <br>But nevertheless good project.
Great ible ! I love recycle projects like this, there are so many items out there for re-use. This whole project couldbe done using all recycled parts. It is genious in its simplicity. Two thumbs way up!
no one can say that it is not a bright idea!
I have to echo the concern regarding reusing the power inlet. <br>Connecting what is clearly a mains power input to the battery terminals is VERY DUMB. <br>Someone, (perhaps even you in a while when you forget how it's wired), will connect this to the mains and the results will be ugly. <br>Good design is first and foremost inherently safe. This is an accident waiting to happen.
Why not LED? Much more bang for your battery!
Good idea! <br>One suggestion: <br>It has enough space to put the charger in the box! <br>The charger also does not weigh that much! <br>Then, to load only necessary to use a standard PC cable.
I must have 5 leftover power supplies lying around waiting for projects just like this. What a great idea!
you have enough room to add a small 12v transformer and a few diodes and you could plug it in to recharge the battery.
I love the idea. Any computer geek will instantly recognize it. My only suggestion is to twist the &quot;handle&quot; wires so they will be more like a rope...?
Isn't it very Dangerous whir the normal Power Plug?
Unfortunately instructables is not policed for safety issues, there are some really dumb reuses of mains fittings on here. I should create an instructable of a cut off mains cord to use as a child's toy :p. I'm not the intructables safety police either but when I see things like this I cringe most likely as you did! :) At least one of the terminals used was the earth and hopefully the other was neutral (assuming the plug/socket etc is wired correctly) so inserting a mains cable will either rapidly blow a fuse/trip somewhere or short the battery across the house wiring? I wouldn't want to be the one to find out ;)
whenever I need a charger, switching power supply, or the like, I can usually find one at my local Habitat for Humanity store for next to nothing. Everything from 3v to 24v has been there at least once. <br> <br>good value for you and for the community
I like the steampunk hint to it i think you should go all out and steampunk the whole thing
Items that I make from recycled, salvaged, and junk materials tend to have a certain look about them.<br> I actually have a term for this; it's <strong>&quot;Junk-Punk&quot;</strong>.<br> Please feel free to use this term and share it with all your friends.
ok thats really cool, alot of my friends are on instructables and ill tell them to follow you. i like your stuff its awesome
Thanks Chase!
This is all kinds of awesome! Did you consider mounting the battery charger inside of the case and using the power supply's cable to charge?
I didn't, just because I already had a &quot;wall-wort&quot;-style charger that is already exactly the right charger for this battery. However, I really LIKE the idea of having an integrated charger, just because it would be so cool just to run the power cord right from the wall into the power supply.
<br> Sometimes a lower light level, is all you need to be able to navigate around a room.<br> You could use the 115/230 switch to put&nbsp;a resistor, into the circuit, so you&nbsp; could have a hi/lo setup.&nbsp;
that looks pretty cool
very creative.
Nice one. Very cool looking. <br>I wish your future version uses power LEDs.
Looks great! But is it heavy?
I'd say it's &quot;Hefty&quot;. <br> <br>It's not particularly light, but hangs very nicely from the handle. It has a sense of solidness to it.
Good for bashing zombies....
very cool voted for
Great idea! <br>
LEDs would not work better?
LEDs are wonderful things, but don't confuse efficiency for practicality or light output. <br> <br>I already had a 12V bulb just kicking around, and it lights up a large area. <br> <br>To purchase an LED/LEDs with the same light output, it would have been significantly more expensive, more time spent soldering, etc. etc. <br> <br>If you already have some high-output LEDs laying about unused, they would be GREAT to use in a similar project.
A possible improvement to his project would be to assemble a rectifier and regulator so it can be charged directly from the wall using an IEC cord.
This is really cool!

About This Instructable




Bio: Ordinary guy with no special skills, just trying to change the world one backyard invention at a time. See more at: http://300mpg.org/ On ... More »
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