How to Make a 30w Mega Flashlight

Hi,In this intructable I show how to make 30w mega flashlight

Step 1: Led and Heatsink

first we need a 30w smd led chip and a heatsink.I mount led on the heatsink with screws.and don't forget to add some thermal paste.

Step 2: Adding Fan

I add a fan for more cooling it works good.

Step 3: Making the Box

I maked a box with hardboard for the led.

Step 4: Adding Switch and Female Connector.

added a normal on/off switch and a female power connector for charging the battery.

Step 5: Mounting the Led Into Box

mounted the led into box with screws.

Step 6: Bushes and Screws

Need 4 rubber bushes and 4 screws for base.

Step 7: Drilling the Hole

drill hole in the centre for screws.

Step 8:

mounted the rubber bushes

Step 9: The Battery Pack

Step 10:

mounting battery with double side tape.

Step 11:

Adding a metal sheet for xtra strong.

Step 12: Battery Charger

Iam using a automatic charger with thermal protection.It's output voltage is 12v.so that we can charge 11.1v battery.

Step 13:

Wiring the battery charger and battery.

Step 14:

This is a diy battery level indicator.The ic I used is 3914.If anyone want the circuit diagram comment below I will give you.

Step 15:

final wiring.

Step 16:

make a metal clamp for more strong.

Step 17:

close the top cover and glue it using hot glue.I added a on/off switch and a push on switch.

Step 18: Painting

painting using sparypaint iam using black.

Step 19: Final Look

I added a handle.

Step 20:

Battery level indicator at night

Step 21:

charging before the use charging voltage 230v ac

Step 22:

without led and with led

Step 23:

Without any light,with a regular torch and my mega flashlight.

Step 24:

regards,

Electro maker.