The Green Helmet (Solar Powered, Safety Lit, Weatherproof Bike Helmet.)

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About: YouTube: www.youtube.com/c/calebjc

A solar powered, trickle-charged, weatherproof, safety bike helmet with changeable parts.

> See 45 second video of helmet
> 2-minute video of construction and use
> Charge time: 5-8 hours in full sunlight to charge 4 AA batteries. I used 3 AAA batteries, so it charges in more like 4 hours. It will charge in bright cloud cover as well.
> Runtime being tested, but so far, seems like several hours.
> Replaceable 5 or 10mm LEDs, flashing or not, in O ring sealed mounts.
> Flexible weatherproof solar panel.
> Detachable batteries and panel for use as a AAA battery charger for camping equipment like headlamps that use 3AAA batteries.
> Removable the AAA batteries can be easily taken out and charged in wall if needed, or regular AAAs can be used.

I thought this would be a well-suited application of solar powered trickle charge panels. I only ride at night about an hour a week, so during the day the helmet can sit in a window and charge. Helmet mounted lights also free me from having lights mounted on my bike that need to be detached to keep from being stolen. It works in the rain and so far is always charged when I need it.

This project could be done in many different ways and I spent a lot of time trying different parts and ideas. The key breakthroughs for me were to use 3 AAA batteries, vs the 4AA's that came with the Solar Panel because they were a better balance of weight to the right amount of power and milliamps. I ended up using a simple soft case Velcro wrapped to the helmet, and relied heavily on Black Shoe Goo! (I think it's the new duct tape). Most of the work was getting an easy rapid prototype idea to work rain or shine, for months on end, and be versatile with replaceable parts. I kept it flat black because the helmet is flat black, so chips don't show. And I'm in New York City, where black is the default color.

Good luck! Let me know if you come up with better ideas.

Caleb John Clark. Made at NYU, Tisch School Of The Arts, ITP dept. for Build in Despina Papadopoulo's Softness of Things class
Oct. Nov. 2007

> My Portfolio
> my TechTrek.Tv show

Step 1: Parts & Tools

Tools: Basic electronics tools. Wire cutters/strippers. Sander or file. Heat gun. Electrical tape. Solder iron. Breadboard might be nice for testing, but not needed.

Parts:

Helmet: Bern black Brentwood with visor pads for summer: http://www.bernunlimited.com/2007/brentwood.html

Solar Charger: Flexible Solar Battery Charger SolLite-4AA by Silicon Solar. (I used a different case with 3 AAA batteries). http://www.siliconsolar.com/Flexible-Solar-Battery-Charger-SolLite-4AA-p-16199.html

LEDs
> 2, Giant 10mm Rainbow Flashing LED: Flash slow, then fast, through red, green and blue. Electronic Goldmine: http://www.goldmine-elec-products.com/prodinfo.asp?number=G16226
Or if you want a longer run time, use regular single color flashing 5mm bulb, say green in color from the sites below.
> 2, Red Clear 10mm Flashing LEDs. Electronic Express: http://www.elexp.com/opt_6bid.htm
> 2, Yellow Clear 10mm Flashing LED. Electronic Express: http://www.elexp.com/opt_6bid.htm
LED Mounts
Waterproof, replaceable bulb mounts. Takes 5mm or 10mm bulbs.
6, White 10mm 24 inch wired mounts: 593-CNX460X24124 CNX460-X02-4-1-24 VCC LED Lens Mounts from Mouser Inc. http://www.mouser.com/search/ProductDetail.aspx?R=CNX460-X02-4-1-24virtualkey59300000virtualkey593-CNX460X24124

LED Mount Lenses
Clear Water Tight O-ring Fresnel lenses: 593-HMS462CTP HMS462CTP VCC LED Lens Mounts: Mouser Inc. http://www.mouser.com/search/ProductDetail.aspx?R=HMS462CTPvirtualkey59300000virtualkey593-HMS462CTP

Battery holder/switch
Radio Shack: "AAA" Battery Holder (Holds 3 Batteries)
Item #: AC-1100-270-0412
http://www.trossenrobotics.com/store/p/3544--AAA-Battery-Holder-Holds-3-Batteries-.aspx
Switch: Radio Shack DPDT Submini Slide Switch. Model: 275-407
http://www.radioshack.com/product/index.jsp?productId=2062491&cp=2032058.2032230.2032278&pg=2&parentPage=family

Batteries
3 high quality rechargeable AAAs, Ni-Cad seems the choice of lots of solar products.

9 volt battery snap connectors
2, nine volt battery connectors. http://www.radioshack.com/sm-fully-insulated-9v-battery-snap-connectors--pi-2062219.html

Soft Case: Case Logic MP3 Mini Disc Player Shuttle: http://www.caselogic.com/small_mp3_player_shuttle/product_detail/index.cfm?modelid=56457

Black Shoe Goo: To fill in around mounts and reinforce/waterproof solar panel connectors, and soldering and switch on battery holder: http://lifehacker.com/software/household/shoe-goo-super-glue-157137.php

Standard 'gap filling" super glue for LED pre-Shoe Goo mounting, wiring and reinforcing Velcro edges

Standard Black Double sided Velcro

Reflective Velcro bike wrap

black shrink tubing (electronic stores)

Krylon ultra flat black spray paint. (hardware stores, could use gloss Krylon "Fusion" paint too)

Step 2: Install LED Mounts in Helmet

Before you start gluing, test the LEDs in a bread board, or 3AAAs in a case, or a 4v power source, just to make sure it all works.

The Shoe Goo is for holding and building in the mounts, but also the mounts are placed so as to let air in the front two vents still, and a little out the back and top. You could put lights in all the vents I suppose. Or skip the top ones altogether.

1. Sand 2 of the LED mounts ribs off on two sides. These are for the top two lights so they fit into the tight vents

2. Super glue the six mounts into the vents. I used "gap filling" supper glue. Super glue dries fast, so place them where you want them and then hold them until the glue sets. Let dry. Make sure the O rings can be unsqrewed!

3. Shoe Goo in the big holes. I had to do one at a time since Shoe Goo flows with gravity. So I mounted the helmet in a vise, with one vent pointed up, taped the backside of the helmet's vent, and filled the gaps. Then let it dry for 24 hours. Then repeated for each vent.

4. Spot super glue wires into the air vents of the helmet.

5. Put another layer or two in vents where the Shoe Goo settled.

Step 3: Reinforce Solar Panel

I broke my first solar panel from moving around the leads that connect to the panel too much.

On my second panel I reinforced the leads with...what else...black Shoe Goo! Both on top and underneath.

Step 4: Velcro

Now it's time for putting the Velcro on the Panel and helmet. It doesn't really matter if you painted or not. You'll have to paint as a last step anyway.

1. I put the fuzzy side of the Velcro on the Solar Panel. I don't suppose it matters. Either way, start with the panel. I used six pieces of Velcro running perpendicular to the where the wires leave the panel, and dealt with the overlap at one end vs. ripping the last piece. It's hard to cut.

2. Mount other Velcro side to the Panel's Velcro, NOT the helmet, this will insure alignment.

3. With the solar panel's bottom showing the sticky (as in glue) side of the Velro, place it squarely on the top of the helmet. Press down hard on all sides.

4. Separate the solar panel from the Helmet, leaving one side or the Velcro on the helmet. Now fix up the helmet Velcro.

5. I edged both the solar panel's Velcro and the helmet's Velcro with super glue. I figured it would keep water from seeping in, but also mean I could someday get the Velcro off of the helmet much easier then if it'd glue down the Velcro on the entire surface.

Step 5: Wiring

I tried 3 different tactics for holding the back batteries. First I tried solid plastic containers for holding wallets when camping/rafting. I was going to mount them directly to the helmet, but be able the take the batteries out of the container. After sever cases and lots of glue, it proved not the way I wanted to go. So I found the little soft case to Velcro on, much better. Could even be smaller.
Either way, the wiring is pretty simple since there's no chip.

1. Get the six white and six black wires twined together.

2. Put on some shrink tubing, like 4 inches.

3. Solder and electrical tape about 8 inches of red wire to the white wires, and black wire to the black wires.

Battery holder to panel connection

Use the black and red wires that come with the battery holder to attach to the solar panel's wires I kept them slaved together since I figured I'd have the batteries with the panel mostly, but you could put any kind of connection. You're going to need an extension of wire too, so two solder joints.

I went from 4 AA's to 3AAAs because it worked fine and was light. I think you'd need about a 150ohm resistor if you went with 4AA's because I burnt out a bulb or two.

1. Cut the 4AA charger that came with the panels. (or if you don't mind the weight, just use it. But beware of the watts, they can blow LEDs)
2. Solder about 8" of red and black wire to the panel's wires. Tape.
3. Put on about 8" of shrink tubing over the joint, close to the panel.
4. Run the wires up into the battery case's hold for ear phones.
5. Then solder to the AAA battery holder's wires and tape.

Power and Switch
Now we've got to get the power to the lights and put a switch in. You could use a variety of switches and cases here, but here's what I did.

1. I carefully soldered red and black wires of a standard 9volt battery clip to the battery case's leads at the same place the leads that came with it attached. However, since I used 9volt battery clips to make it detactable, I soldered Red to black, and black to red And be very careful not to melt the plastic. I did, and had to buy another holder. Cover everything with black Show Goo. Let dry.
2. I mounted the switch with...you guessed it - Black Shoe Goo! Be careful not to glue the switch though. I had to stand around moving it every once i while until the Goo set. You could also super glue it, but that ruined one switch for me.
3. Cut the black wire and wire it to the switch on both the 9volt clip end and the battery case end. Solder, cover with more black Shoe Goo!
4. Once it's all wired, and it works, heat gun the tubing to tighten it around the wires.

Step 6: Paint

Now a final coat of ultra flat black paint and we're done. I used ultra flat black to match the original paint on the helmet, the black Shoe Goo, black solar panel, and black case. This way cratches won't be visible. You could use any color though, if you put a few coats on.

1. Buff, bondo, Shoe Goo, very carefully sand, any bumps or blemishes.
2. Detach panel and case.
3. Tape up Velcro to cover
4. Take off O ring lenses and wrap LEDs in tape, or take out LEDs and cover holds they go into.
5. Wash with rough sponge, rinse, dry
6. Spray paint. Let dry a full night.

Ride!

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    61 Discussions

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    calebjcedina2015

    Reply 7 years ago on Introduction

    If you hit the panels, yes. But I hear one should get a new helmet after a crash anyway. This helmet was not modified at all structurally, the lights were put in existing vents. I would not cut or modify any helmet personally ,as it can change how safe it is. If you can, embed the lights deep too, so the don't catch on anything as Pellepoloton pointed out.

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    pellepeloton

    10 years ago on Introduction

    Is this a safe helmet I ask? First, it looks like an old helmet without slippery hard shell? I have seen a lot of helmets where the original plastic cover has fallen off so it only has polystyrene shell left. Hit your head into asphalt and it does not slide but grips and twists your neck!! I will not speculate what will happen next. Secondly, those added modifications stick out, and in the case of hopefully unlikely accident or even hitting a tree with your helmet, it will get caught causing your head to twist? The primary purpose of any helmet is to protect the wearer from shocks and reduce the possible injury and any modification added into helmets may compromise these.

    11 replies
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    YellowRexYerboogieman

    Reply 8 years ago on Introduction

     I hope someone deserving gets your organs.

    No helmet bikers (motor or otherwise) make the best donors.

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    YerboogiemanXellers

    Reply 10 years ago on Introduction

    i don't know, but i just saved a bunch of money on my car in....im using the new Google chrome. they're uncomfortable and hurt my head, although its probably going to hurt my head even more when i crash on pavement. its a lose/lose situation.

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    Redgerrpellepeloton

    Reply 10 years ago on Introduction

    it looks prety safe to me :O i imagin that it is one of those really expenceive ones that they modified, it looks like one of mine. also it could be a skatebord helmet, they are made differently but do about the same thing :O hope i helped :O

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    calebjcpellepeloton

    Reply 10 years ago on Introduction

    As I've said, the modifications might compromise the safety I think. I'm not qualified to judge that, but I didn't cut the helmet at all or alter its structural integrity, and the lights might break off before the helmet broke, I'm guessing. This was a school project and made for New York City night riding in the wilds of Manhattan.

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    callmeshane

    11 years ago on Introduction

    This is actually really well done... Pity someone isn't making helmets with thin recess's in them to take a a couple of AAA batteries. I ride my bike all the time... and it's great.... BUT.. I don't agree with bad (read exceedingly stupid) fashion trends - such as using "all black" helmets (and other clothing) on bicycles, ESPECIALLY at night.... Of all the cumulative things that you can do to keep yourself from getting run over, wearing black or dark colored clothing, this is probably the dumbest, along with no lights at all. Once many years ago, there was a new industrial estate going up near where I lived. And it had a stretch of dead flat very wide and absolutely straight and mostly unlit road... about 3km of it. So no people, no cars, no houses... no cops.... and in the middle of the night...... So I opened the motorbike up a bit... And my bike was as loud as.... with the throttle opened up - a tad... I had my lights on and everything..... And right in the middle of the road, some idiot of a kid, with NO lights, NO reflectors, WEARING BLACK pants and sweater and helmet... This idiot rode off the footpath and straight across the road - right into my path.... I was only speeding a little bit...... not much... And I had to BRAKE HARD and SWERVE to stop from running right into him..... And the thing is that because of the lack of lights and the way he was dressed, and he came across the road from the footpath, in an unlit area..... I was not able to see him, until he was just about wrapped around the front of my motorbike...... I still to this day, regret not having gotten off the bike and having beaten the daylights out of them, instead of coming back to yell at him.... "Get some some fucking lights" So just because all the other idiots use black colored helmets, doesn't mean you have to as well.... The trend or fashion for wearing BLACK helmets, is a stupid thing for stupid people. SAFE cycling counts, High visibility and being EASY to see, make for a lot of survival bonus points. Accumulate them.

    5 replies
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    callmeshanecallmeshane

    Reply 10 years ago on Introduction

    This kid on the bike in all black with no lights, on the unlit street.... he came fast from the side of the road and I had like a second or so of vision to brake and swerve.....

    If had not of braked HARD and swerved I would have hit him square on and he WOULD have died..... and I would have wrecked my bike, probably have hurt myself a bit and then had heaps of problems with the cops and the paperwork and all that.... and these are MAJOR hassles I just don't need.....

    My bike is a BIG BMW Desert bike with crashbars and all.... and it has pretty good head lights...

    Black clothing - it almost TOTALLY absorbs light.....

    Toss in background lighting and other distractions and car drivers generally are going to have a hard time seeing you, until you become a hood ornament.

    One of the BEST night time clothing accessories is to go to the clothing recyclers, and buy some larger BRIGHT WHITE cotton business shirts....

    They fit over everything, they ARE highly visible and they are cheap...

    A few of the red and white and yellow prismatic reflective tape strips on the WHITE helmet...

    Toss in front, side and rear reflectors and good head and tail lights...

    And some reflectors in the spokes.....
    Bicycle Victoria is a self organised collective of bicycle groups and it runs some big shows.....

    And even they are pushing to crunch people who ride without lights... Although I think fining people is unproductive, and making them pay for a NEW set of lights, is productive, never the less what I once saw - like a FOOL, as impingements upon my liberties and intelligence, that these "safety things" are generally well thought out, practical and very good things to do and have.

    The stats for fatal and serious injuries without lights are pretty bad......

    http://www.bv.com.au/bikes-and-riding/40519/

    Increase the fine for riders without lights

    Bicycle Victoria today has called on the Victoria Police to increase the penalty for cyclists riding without lights.

    The call, on the shortest day of the year, comes after a recent Bicycle Victoria survey revealed that more than a quarter of bike riders are riding on roads at night without proper bike lights.

    Despite a three-year campaign to get riders to use lights, Bicycle Victoria is disappointed that there has been no change in the proportion of riders without lights in the run up to the shortest day of the year.

    Harry Barber, CEO of Bicycle Victoria said today, “We are now calling on the police to raise the fine to one penalty point or $108 for riders who do not have working lights at night.”

    The current fine is half a penalty point - $54.

    Mr Barber said a higher deterrent was needed to make riders understand that riding at night without lights increases the risk of collisions and road trauma.

    “Our surveys indicate that around a third of all fatal collisions are related to dark conditions,” said Mr Barber.

    In Victoria, between 2000 and 2005, a quarter of all collisions (23.56%) leading to riders being killed or hospitalised were in dark conditions.

    • In 2004 four of the eight cycle fatalities occurred at night or in semi-darkness and involved cyclists riding without lights or with inadequate lighting. (VicRoads June 2006)
    • In 2005 none of the seven fatalities were associated with lights or light conditions
    • In 2006 five of the thirteen cycle fatalities occurred at night or in semi-darkness

    A survey of 4 500 drivers in Queensland confirmed that motorists find it frustrating when bike riders don’t use lights at night. The survey (RACQ October 2006) put riders without lights at night at 7th on the top ten annoying things for motorists. In this survey, riding at night without lights was the bike rider behaviour that was most annoying for drivers.

    This is a good read... a little superficial in comparisions..

    http://www.vicroads.vic.gov.au/NR/rdonlyres/88D0CF95-19BF-426F-A5DC-DE7255BFFF56/0/CycVisibility.pdf
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    A good namecallmeshane

    Reply 10 years ago on Introduction

    Dude, chill out. Wearing a black helmet isn't going to kill you. Wearing all black on a black bike without reflectors or lights is. Just because the guy's helmet is black, you don't need to freak out on him.

    Not to mention those light on the helmet which were the focus of the instructable. Why are we worrying that he used a color to blend in with the SHOE GOO?

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    Rimwulfcallmeshane

    Reply 9 years ago on Introduction

    I had black jacket that I wore but it was striped with gray reflector material so I was seen.