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Step 5Wiring
I tried 3 different tactics for holding the back batteries. First I tried solid plastic containers for holding wallets when camping/rafting. I was going to mount them directly to the helmet, but be able the take the batteries out of the container. After sever cases and lots of glue, it proved not the way I wanted to go. So I found the little soft case to Velcro on, much better. Could even be smaller.
Either way, the wiring is pretty simple since there's no chip.
1. Get the six white and six black wires twined together.
2. Put on some shrink tubing, like 4 inches.
3. Solder and electrical tape about 8 inches of red wire to the white wires, and black wire to the black wires.
Battery holder to panel connection
Use the black and red wires that come with the battery holder to attach to the solar panel's wires I kept them slaved together since I figured I'd have the batteries with the panel mostly, but you could put any kind of connection. You're going to need an extension of wire too, so two solder joints.
I went from 4 AA's to 3AAAs because it worked fine and was light. I think you'd need about a 150ohm resistor if you went with 4AA's because I burnt out a bulb or two.
1. Cut the 4AA charger that came with the panels. (or if you don't mind the weight, just use it. But beware of the watts, they can blow LEDs)
2. Solder about 8" of red and black wire to the panel's wires. Tape.
3. Put on about 8" of shrink tubing over the joint, close to the panel.
4. Run the wires up into the battery case's hold for ear phones.
5. Then solder to the AAA battery holder's wires and tape.
Power and Switch
Now we've got to get the power to the lights and put a switch in. You could use a variety of switches and cases here, but here's what I did.
1. I carefully soldered red and black wires of a standard 9volt battery clip to the battery case's leads at the same place the leads that came with it attached. However, since I used 9volt battery clips to make it detactable, I soldered Red to black, and black to red And be very careful not to melt the plastic. I did, and had to buy another holder. Cover everything with black Show Goo. Let dry.
2. I mounted the switch with...you guessed it - Black Shoe Goo! Be careful not to glue the switch though. I had to stand around moving it every once i while until the Goo set. You could also super glue it, but that ruined one switch for me.
3. Cut the black wire and wire it to the switch on both the 9volt clip end and the battery case end. Solder, cover with more black Shoe Goo!
4. Once it's all wired, and it works, heat gun the tubing to tighten it around the wires.
Either way, the wiring is pretty simple since there's no chip.
1. Get the six white and six black wires twined together.
2. Put on some shrink tubing, like 4 inches.
3. Solder and electrical tape about 8 inches of red wire to the white wires, and black wire to the black wires.
Battery holder to panel connection
Use the black and red wires that come with the battery holder to attach to the solar panel's wires I kept them slaved together since I figured I'd have the batteries with the panel mostly, but you could put any kind of connection. You're going to need an extension of wire too, so two solder joints.
I went from 4 AA's to 3AAAs because it worked fine and was light. I think you'd need about a 150ohm resistor if you went with 4AA's because I burnt out a bulb or two.
1. Cut the 4AA charger that came with the panels. (or if you don't mind the weight, just use it. But beware of the watts, they can blow LEDs)
2. Solder about 8" of red and black wire to the panel's wires. Tape.
3. Put on about 8" of shrink tubing over the joint, close to the panel.
4. Run the wires up into the battery case's hold for ear phones.
5. Then solder to the AAA battery holder's wires and tape.
Power and Switch
Now we've got to get the power to the lights and put a switch in. You could use a variety of switches and cases here, but here's what I did.
1. I carefully soldered red and black wires of a standard 9volt battery clip to the battery case's leads at the same place the leads that came with it attached. However, since I used 9volt battery clips to make it detactable, I soldered Red to black, and black to red And be very careful not to melt the plastic. I did, and had to buy another holder. Cover everything with black Show Goo. Let dry.
2. I mounted the switch with...you guessed it - Black Shoe Goo! Be careful not to glue the switch though. I had to stand around moving it every once i while until the Goo set. You could also super glue it, but that ruined one switch for me.
3. Cut the black wire and wire it to the switch on both the 9volt clip end and the battery case end. Solder, cover with more black Shoe Goo!
4. Once it's all wired, and it works, heat gun the tubing to tighten it around the wires.
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