This is a simple instructable on how to make a flashlight out of shop room junk. No money was spent on this project and all parts were sourced from recycled electronics, car parts, or recyclables.
Step 1: Parts Used
For the container i used a coffee can from the recycle bin.
The toggle switch came from a failed project i scrapped for parts
Electrical wire is from a computer case fan that was burnt out. It had enough wire on it to scrap for this job.
for the light i used the LEDs out of a hardware store $2 flashlight. The flashlight was broken (bad on/off switch) so i extracted the LEDs from it.
The lens for the light came from a 2000 Sonata headlight assembly. It is made of glass.
Step 2: Cutting the Hole for the Lens.
To mount the lens i cut a hole in the bottom of the coffee can that is about 1/4in smaller than the lens itself. A few drops of super glue to set the position of the lens on the can and then applied some thick adhesive placing the decorative metal ring over the glue.
Step 3: The Light.
To get the LEDs out of the flashlight i removed the batteries and used a socket and extension. By tapping the socket onto the ground it forced the LED board out the front of the light.
I removed the spring off the back of the circuit board and replaced it with a wire. This is the positive lead.
The negative lead is on the outside of the board. I soldered a wire to it and tested it with the 9v battery to make sure i got it correct.
Step 4: Mounting the Light, Switch, and Battery.
So the bit of metal i had was not big enough to perfectly fit in the can. I taped it to a can lid to make the size right. The light is mounted about 4in behind the lens.
Using my rotary tool i made a hole for the switch.
After all the parts are fitted they are glued in with a strong adhesive.
The wiring is very simple. negative from the light goes to the negative on the battery.
Positive goes from the light to the switch and then to the battery positive.
Step 5: Adding a Handle and Testing.
To add a handle to the light i poked some small holes in the plastic. using a length of wire i pushed the ends of the wire into the holes and tied a knot on the back side.
The light works great. The lens on the light makes the cheap hardware store LEDs put out a wider beam of light. The running life of the light on one 9v battery is about 10 to 12 hours.
Step 6: Test Video.
To let everyone see how well the light works here is a video of me using it in the shed. Subscribe to my channel to see more cool builds!