Introduction: DIY HEADLAMP

A headlamp from a flashlight head and CFL base.

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Step 1: Arrange a Broken Flashlight

Dear All,

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.

Starting off...

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

  1. it was round and the perfect shape
  2. it is not all heavy and weighs in at may be 30grams or so.
  3. is black in colour , which I like
  4. 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:

  1. Check the width of the metal pins which protrude from the switch
  2. cut a slit as shown in the pic so that the SPST switch's pins are tight enough not to fall out on jerking.
  3. Slide the switch in and proceed to solder the pins.
  4. 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.

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