Introduction: Long Lasting Ultra Small Super Bright Bike Flashlight
After trying unsuccessfully several commercial bike flashlights, I decided to make me one that cover my needs:
- Lightweight and very small size.
- Rechargeable to prevent the continued waste of AA batteries.
- Cheap!!!
- Powerful and long-term for long night cycling routes.
- Lightweight and very small size.
- Rechargeable to prevent the continued waste of AA batteries.
- Cheap!!!
- Powerful and long-term for long night cycling routes.
Due to my limited knowledge of electronics, I assume that the circuit can be improved, so any help comment or suggestion with this, will be welcome ;)
Step 1: Materials Needed
- Old Cellular phone with working battery and charger (as charging station).
- Rf switch cable TV adapter from an old video game console or some similar size plastic case.
- Hard disk or some electronic device with contact pins.
- A small switch
- 10 white ultra bright leds with prototyping board for welding circuits.
- Solder
- Bicycle clamp from a broken bike light
- Wire
- Rf switch cable TV adapter from an old video game console or some similar size plastic case.
- Hard disk or some electronic device with contact pins.
- A small switch
- 10 white ultra bright leds with prototyping board for welding circuits.
- Solder
- Bicycle clamp from a broken bike light
- Wire
Step 2: Lights and Case
- Place the leds in parallel on the prototyping plate as shown in the picture.
| - +_|_+ - |
| - +_!_+ - |
| - +_!_+ - |
| - +_!_+ - |
| - +_!_+ - |
|__---|--__|
| |
+ -
- Open the RF adapter and remove the inside circuit / wires to get the plastic box empty .
- Take measurements of the led board and cut / sand the plastic box until led board fits perfectly into.
- Unscrew the clamp from the old bike light.
- Mark in the plastic box where to screw the clamp and make the screw holes.
- Screw the clamp to the box ensuring it is firmly attached.
| - +_|_+ - |
| - +_!_+ - |
| - +_!_+ - |
| - +_!_+ - |
| - +_!_+ - |
|__---|--__|
| |
+ -
- Open the RF adapter and remove the inside circuit / wires to get the plastic box empty .
- Take measurements of the led board and cut / sand the plastic box until led board fits perfectly into.
- Unscrew the clamp from the old bike light.
- Mark in the plastic box where to screw the clamp and make the screw holes.
- Screw the clamp to the box ensuring it is firmly attached.
Step 3: The Battery Holder
- You must find a good way to attach the battery that allows you to easily replace to charge it.
- I have chosen a pin connector from an old hard drive.
- Unscrew the pin connector from the hard drive and remove some pins until you have only the positive and negative pins and a pair more for holding the battery.
- Sand the pin board until it fits into the plastic case.
- Solder wires to + and - respectively.
- Solder the positive wire from the pin board to the positive leg of the led board.
- Solder the negative wire from the pin board to the switch and from the switch to the negative leg of the led board.
- I have chosen a pin connector from an old hard drive.
- Unscrew the pin connector from the hard drive and remove some pins until you have only the positive and negative pins and a pair more for holding the battery.
- Sand the pin board until it fits into the plastic case.
- Solder wires to + and - respectively.
- Solder the positive wire from the pin board to the positive leg of the led board.
- Solder the negative wire from the pin board to the switch and from the switch to the negative leg of the led board.
Step 4: Finishing...
- Put the battery inside the plastic box making all components fits well and the polarities are correct.
- At this point, maybe you will need to adjust the position and size of the inside components, so sand if you need before gluing the pin board!!!
- Turn on the switch and check if pin board makes good contact to the battery...
- If it works correctly, it's time to glue the pin board to the plastic case ;)
- Close the plastic case and plug the bike clamp...
Ready to go!!! ;)
When the battery runs out after SEVERAL hours of use, all you have to do is remove the battery and place it on the phone to recharge again...
- At this point, maybe you will need to adjust the position and size of the inside components, so sand if you need before gluing the pin board!!!
- Turn on the switch and check if pin board makes good contact to the battery...
- If it works correctly, it's time to glue the pin board to the plastic case ;)
- Close the plastic case and plug the bike clamp...
Ready to go!!! ;)
When the battery runs out after SEVERAL hours of use, all you have to do is remove the battery and place it on the phone to recharge again...