so I sketched my plans, invested and cashed in some friend-checks, and now it it is built.
This is what I use today when traveling down to the really big caves with the heighest ceilings :) and it works perfectly!
on request I made my own small instructable to take interested people through the process.
looking back on the costs of making this lamp, I managed (hand on heart) to get it down to:
LED´s - 25$
Buckpuck driver - 30$ (shipping included)
Battery case - 3$
Some new batteries, 4 of them - 28$
The casing was for free - YES! YES! YES! - thx Robin!!!
which bring the cost down to 86$. I would say a GIGANTIC leap from the 300-400$ pricerange of a more serious headlamp from for example Petzl, Silva or Black Diamond.
And it really really REALLY does deliver the same amount of light as they do.
The only drawback might be that the batterylife for the expensive ones is longer, but if you switch up from standard AA to LIthium batteries ( as I will do ) you should get even more for the small amount of money you put into it.
Step 1: Design
The picture of how to draw the wires is just a copy from that of dan´s. but it was a good idea to repeat it to myself.
my thoughts on the design was that it should be as small as possible, but with enough aluminium around the LED´d to take away the heat. And to get a design that is not already on the market is not too bad either. :D
By a crazy coincidance, i found when sketching, that a danish "1 krone" coin has if traced around with a pen, almost the exact same diameter of an luxeon 1w LED. So I used it for my drawings. :)
Working with CAD software ( the working part is done by my friend Robin ), my idea of an aluminium casing came one step closer to the real world, with a 3D model.
My thought was to leave room for a plexiglas sheet to protect the lenses from scratches, it would be held in place by 4 screws, or bolts or whatever. the plexiglas sits on a lowered ledge to not stick out and take the beating of rocks and dirt in my way, when crawling underground.
The smaller sketch of a lamp with only 2 LED´s is in the making today. :)