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This is my first Instructable and since I don't want to be left in the dark I decided to enter the Flashlight Contest with a flashlight that is both rechargeable and waterproof.

Step 1: I Need to Start Somewhere.

I started of by gathering all the parts I needed. In this case I had most of the part except the  two threaded pipe fitting and the 12V bulb. I got those at my local hardware store. I also needed a threaded end cap but they had none in stock. The bulbs are just like the regular downlight bulbs but they do not heat up like the regular bulbs, the use less energy and last longer. They will also withstand bumps and knocks better. I sourced a 12V rechargeable battery from a old RC car.

Parts List
50mm PVC Pipe
PVC Cement
50mm Threaded PVC Fitting x 2
Threaded PVC end cap Fitting
Smallish Toggle Switch
12V 24LED Downlight Bulb (They are available in different colours)
12V  rechargeable battery
Small piece of foam
Tape, Cable ties and heat shrink

A 9V battery will also work but the the light won' t  be that light or battery holder may also work if you can get it to fit and it has enough power example 8 1.5V AA batteries.

Tools
Hacksaw
Soldering Iron
Solder
Diagonal pliers (I had to look this one up, I know them as a Side Cutter - http://en.wikipedia.org/wiki/Diagonal_pliers)
File
Sand Paper




Step 2: Making Things Work

I had to make my battery fit and to do so I had to roll it up. The battery is basically 10 1.2V AA batteries joined in series. I just had to cut the plastic wrapping and tape it together. A step that I did a few months ago was to add two wires that came of the battery. I just soldered them to pins on the connector. I also decided to solder solder a wire on to the bulb instead of a connector seeing that there are less to go wrong. Polarity didn't matter since downlights usually powered by alternating current . All I then had to do is wire everything up to a switch. 

I tested that everything was in working order and taped it all together.I have added a wiring diagram for those who have fialed to get there light or those who are failed to see my spelling mistake.

Step 3: Keeping It All Together

Here I am building my casing from 50mm PVC pipe and fittings.

I hacked of the threaded part and file down it down so that it will give me a flat base to put the flashlight down on. I measured my light  and battery internal working so that I could shorten the 50mm PVC pipe so that access the ON/OFF switch and the battery plug from the back. Just make sure that you cut at least one end of the pipe square so that the bulb will sit straight.

Something missing from this Instructable is the threaded end cap since my local hardware store was out of stock. I will try a different hardware store tomorrow.




Step 4: Don't Inhale the Glue Vapours

This step is all about the gluing of the parts.

To avoid the shaking of the battery and damaging of the bulb from the shaking battery, I inserted a piece of  insulating foam tubing around the battery up the the bulb. To make sure that there are no water getting in I added a little extra PVC Cement around the edge of the bulb just before i pressed it down into position. 

All I had left to do was to glue the two end pieces on making sure that there is enough glue around the bulb to seal into into place and to keep the water out.

Step 5: Stepping Back

All that's left is to wait for the glue to dry and then I will be following the light.

Using the flash light is simple
- Unscrew the end cap revealing the charging connector and ON/OFF switch
- Turn light on or off as desired
- Screw the end cap back on the tightly to ensure that there will be no water end inside ruining the flash light.

The life of the bulb is a respectable 5.7 years but I left the flashlight on and 2 hour 15 minutes later I felt that the battery was the discharge for any real usable light.


Step 6: TheLost and Found


I added this step, the following day since I didn't have all the parts I needed.

Instead of a end cap, I had to improvise by making a end cap from a female threaded PVC fitting with a glue on end cap.

Following this step will make the flashlight more bulky, but will also add a waterproof storage compartment at the back, for example matches, a small pocket knife or pills.


<p>I really like this. I have a couple of contour brand cameras that I wanted to use for a zombie adventure run but couldn't because they aren't waterproof and I couldn't find anything to use that was reasonably priced. I think this would make a great casing for them instead of the flashlight. Thank you</p>
Great Idea. Typical flashlight designs consist of the light source mounted in a parabolic or other shaped reflector, a transparent lens to protect the light source from damage and debris, a power source (typically electric batteries), and an electric power switch. While most flashlights are hand-held, there are head or helmet-mounted flashlights designed for miners and campers and battery-powered lights for bicycles.<br><br>http://outdoorsolarlightsreview.com/different-outdoor-string-lights-for-your-yard-and-garden-enhancement/<br>
I like it well done. It's quick, it's easy and it works. <br> <br>If I may offer some advice? It could be further developed by using a small slide on/off switch. I believe these are available in a waterproof item. I would use silicon sealant (bathroom stuff) to seal around the switch and also around the rim of the bulb. You could instead use a suitably sized neoprene O ring to seal the bulb (use a smear of petroleum jelly to facilitate closing) and the base. This should then a truly waterproof seal. To what depth (water ingress due to higher pressure) I don't know though. <br> <br>Good ible mate. <br> <br>Take care. <br> <br>Kevan
I love this idea. I was looking for some ideas to make headlight for my bike, but then a bit brighter then most bike-lights are. This idea is great! I'm only curious how many mAh your battery is, because i would like to have a little longer burning time.
Thanks for the comment. My battery was 12V 800mah Nickel-Cadmium Battery pack. If I didn't all ready have the battery pack, I would have gone with 10 of these 1.2V 2300mah batteries (http://www.mantech.co.za/Productinfo.aspx?Item=10M0042) &amp; (http://www.mantech.co.za/datasheets/products/HYMS-AA2300N.pdf) in 2 holder that would be hooked up in series but then I would have changed the design to get the batteries in and out of my flashlight to charge them. In a quick google search I came across this 6v 5000mah battery pack (http://www.all-battery.com/nicd6v5000mahbatterypackforemergencelight.aspx). If 2 of these could be fitted to your bike headlight, then they could last longer than 16 hour according to this calculator (http://www.alternate-energy.net/calcbat06-2.html). Thanks again. Jurie

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