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Do It Yourself
DIY & Home Improvement

DIY mega head flashlight with 6x10W LEDs

DIY mega head flashlight with 6x10W LEDs
DIY mega head flashlight with 6x10W LEDs
This is my new head flashlight. I know it looks a bit strange, but it shines as much as the lights in the car. I installed 6 leds each with 10W. All powered from a 14.4v battery from a cordless drill. This is the most powerful flashlight I have had in my entire life. To build this flashlight I used the previous project ( Diy LED lights panel for 5$ - Cheap and Easy 6 x 10W) where I step by step described how to do it.

Step 1: Components

Components for this project
Components for this project

Step 2: Measuring and cutting

I measured and cut the plexiglass board for electronic circuits.
For cutting I used Hot wire foam cutter from the previous project.
Follow this link to see how I built this tool.
Plexiglass board for electronic circuits.
Plexiglass board for electronic circuits.

Below is an example of plexiglass cutting.

Step 3: Grinding the edges

After cutting the plexiglass the edges are not smooth, that is why I am sanding them.
Sanding plexiglass.
Sanding plexiglass.

Step 4: Drilling holes

Now I can fit plexiglass into a plastic box and drill the mounting holes.
Drilling hole in plexiglass.
Drilling hole in plexiglass.
Drilling holes in the helmet for screws.
Drilling holes in the helmet for screws.

Step 5: Mounting LM2596

Time to mount the LM2596. LM2596 is step down converter and I use this as leds driver.
In addition, I added a rectifier diode, this protects against reverse polarity.
LM2596 - step down converter.
LM2596 - step down converter.

Step 5: Adjust the current on LM2596

Adjust current on LM29. Just now I set the current at 0.5A, it is only for testing.
I use a screwdriver to set the correct current.

Step 6: Putting everything together

Now I can put everything together and test how it works.