I have been watching the evolution of the super bright LED's, I wanted to make a light weight, bright enough for commuting . I also wanted to make it use the light possible batteries with out sacraficing burn time. and the ability to get batteries from 7-11 if need be.
Step 1: Parts
The parts list
Cree LED Q5 emitter ( http://www.dealextreme.com/details.dx/sku.2394 )
Current regulator ( http://www.dealextreme.com/details.dx/sku.3256 )
Lens (http://www.dealextreme.com/details.dx/sku.4626 )
4 AA batter y Holder ( www.bgmicro.com )
an old Pentium 90 with Heat sink
the slot cover from a PC
a SPST switch ,
2 old Coke Caps ( with the points redeamed )
some small screws
tools needed soldering iron, power drill, screw driver and a hot melt gun.
Step 2: LED and Regulator
taking the output lines from the current regulator and solde rthem to the LED star , also solder the power from the batteries to the back side (input ) of the current regulator
Step 3: Heatsink
Next take the Heatsink, remove the pentium and dispose of , and remove the fan too. all you need is the heat sink. Lineup and mak the holes form the mounting screws, make sure you alighn them with the pots from the Lens. next take the PC slot cover and mark the hole for the slot cover . then using a small drill bit ( best in a drill pres ) drill the holes
Step 4: Lens Mounted
put the LED against the back of the heat sink, put the lens ove the top of the LED making sure the posts line up with the drilled holes. once they are lined up screw the Len in to place securing the LED and LENs in place.
Step 5: Attach Slot Cover
take the slot cover and attach using screws. also take on of the coke caps and cut a small notch in it. next take the cap and use the hot melt and attach to the back of the heat sink.
Step 6: Place the Regulator
take the current regulator and put it in the coke cap, amking sure the wire go in the cut notch. Here I made a mistake and put the notch on the top, I should have put it on the bottom
Step 7: Seal the Reulator
I next take the 2nd cap and cut the top off of it and use the hot melt to seal the current regulator in the coke cap.
Step 8: Battery Pack
take the battery pack , and the one I got had a connetor wire , I cut that and put the toggle switch in place. then I used hot melt to hold it in place.
Step 9: Final Assembly
Attach the other end of the wire that is attached to the voltage regulator and attach it to the battery pack. next put a slight bend in the pc slot cover to match the curvature of your helmet. Take 2 pieces of Velcro and Put one stip on the bottom of the slot cover, and the other on your helmet. insert 4 batteries into the Battery holder. I use 2300 MaH NiMh rechargeable Batteries . ( Using recharables best to be greater than 2000Mah .)
Step 10: Place on Helmet
attach on helmet to desired postion and ride. the beuty of this in a pince you can use regular AA batteries .I have been using this for over 2 months commuting every day with out a problem. I even went over the Handle bars Mt biking and the only damage was to my helmet the light was fine.