Intro: DIY HEADLAMP
A headlamp from a flashlight head and CFL base.
Step 1: Arrange a Broken Flashlight
To whoever reads and works as per the steps specified in this instructable, be notified that in no way could I be help responsible for any damage to property, life or any other living or non living object.
We need to arrange a flashlight whose lamp head is not broken and has the light and mirror in working condition.
my flashlight had a loose switch because in INDIA we usually prefer eveready flashlights which are very common.
Newer LED models often come with a slide and touch switch which is essentially a leaf spring type metal strip which completes the circuit when pressed and pushed forward. So it did die but way earlier than I had expected.
The head though, which is essentially a cylindrical screw on type led circuit arrangement was unaffected.
it houses a 10mm led. It is super bright led and comes with just a resistor.
it had to be my choice to make the headlamp because
- it was round and the perfect shape
- it is not all heavy and weighs in at may be 30grams or so.
- is black in colour , which I like
- it has a bright parallel beam.
Step 2: Arrange a CFL BASE and a Switch
I am a CFL lover and often collect circuits from CFLs gone kaput and use them to make other circuits.
I spared the circuit this time though.
I just needed to base for it was to be attached on my forehead with a strap.
The straps are not ready yet and the full headlamp would need some time to materialize.
Also arrange a small switch . Any spst switch will suffice but a smaller one looks way cooler than having a large switch.
off to the next step.
Step 3: Lets Work on Putting the Parts Together
The circuit itself is pretty simple.
Please ensure the Flashlight head fits inside the CFL lamp base.
I had no access to a plastic glue gun and had to use electrical tape.
the Spst switch was from a fly zapper. I collect those too.
the steps involved here:
- Check the width of the metal pins which protrude from the switch
- cut a slit as shown in the pic so that the SPST switch's pins are tight enough not to fall out on jerking.
- Slide the switch in and proceed to solder the pins.
- Solder as per circuit and insulate the joints on the SPST with some plastic glue. DO not use super glue as it could render the switch unusable.