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Good old smudge has stock of protected 18650 li ions and also chargers
Bastid pack is 4 cell 7.4 volt and I think because Smudge does replacement batteries fo r the bastid that he may have leads and connectors for sale
So bastid is 2 parallel sets of 2 series cells?
Smudge packs are the ideal but I'm going DIY light for a reason 😉
I was pointing you at the cable and connectors so you could use the bastid battery .
see your point 😉
I have a helmet torch and bastid on the bars. This will be my new lightweight head torch..
Yes Fozzy, The bastid is a 2S2P battery with a single protection circuit.
I think Troutie was trying to point out I also stock single protected cells and chargers and not just complete batteries.
There was a guy a while ago called TurboFerret who was making and selling protected cell holders which would be ideal for this project. But I havent heard or seen him for ages on here?
Troutie and BCT. Payment sent for the kits.
Thanks guys
Just seen this 3 x 18650 battery holder, although it looks to be pcb mounted.
Supplier: http://search.digikey.com/scripts/DkSearch/dksus.dll?Cat=393250&k=18650
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http://www.batteryholders.com/18650-holders-press-release-Sep09.shtml
http://www.batteryholders.com/BK-18650-PC6.PDF
Although I'm not sure which 18650 batteries would fit or be safest for MTBing?
http://www.dealextreme.com/search.dx/search.18650
Slightly off on a tanget....
HOW addictive is this DIY LED thing? I mean, I thought geeking around with B&Q halogen bulbs, Plumbing pipes and spare bar clamps was fun but this takes it to a whole new level 😉
Thanks to troutie, and the subsequent wave of replies to this (and other) thread(s) I'm lovin it.
If I've done my maths right with my large battery I'll have 8.4 volts x 3.8 amps = 31.92.
Divide this by 7.5 watts should give an estimated runtime of 4.256 hours on full beam less time for battery sagging and voltage dropping.
Jazid: IIRC there was a concern of 18650 cells catching fire or somesuch while charging? I think it was on BR but was a while ago.
Sit back and waits for the wife to ask why I’m giving money away on Paypal whilst wandering why Paypal is setup in her name with my bankcard
Because you got banned from Ebay as well, and had to open up Paypal in her name.
good stuff fellas this is like setting a pack of hounds loose looking for a fox .
and it's turning up some good stuff.
those holders look like they are for protected cells. so it's thumbs up for them
today I am building another helmet light for a mate and whilst doing it am measuring and drawing the bits for my future ref
confirmation of order and paid for. but as yet no dispatch date for the LEDs
got the reflectors yesterday.
Cheers troutie. Well we wouldn't be turning up stuff without the technical support of you, bct and smudge, so glad to give something back!
Can anyone recommend the best/most reliable/inert 18650s from dx?
Jazid
(Becoming a diy light +stw thread obsessive)
Its something I've wanted to do for a while but haven't had a clue where to start so this is great for me. Its a huge credit to you guys who are so willing to spend the time and knowhow to help the rest of us out and what helps make the community so good here.
I'm currently looking for some sort of waterproof pouches for the batteries. I've had a look at [url= http://www.lumicycle.com/product/132/bag/battery-bags-for-li-ion-batteries.html ]LUMICYCLE[/url] and have had a trawl on ebay but nothing really jumped up yet. I may look at making some out of left overs from my goretex over trousers with some velcro straps
Velcro straps here www.aplix.com/en
stay high try tesco s camera bags. they do some cheapies
Fwiw, if you are planning on cutting the hammond box down to size, the 120mm n75al is cheaper(6.7c) than then smaller 80mm n82al(7.99) at maplins
anyone seen if you can get spare end caps as now have a spare half with no end caps.
just a quick question here
I have 2 spare XPE LEDs on the 20mm stars and wondered if anyone was wanting to get one built quick
I have the reflectors and every thing. could post on Monday
same LEDs I have used in the 2 I have done
slightly smaller lumen count and a tighter beam than the Xpgs will produce.
Hammond list a pack of 10 end plates [url= http://www.hammondmfg.com/1455.htm ]HERE[/url] along with some coloured bezels and end plates for those that way inclined.
The 80/54/23 uses this model [url= http://uk.farnell.com/hammond/1455cal-10/enclosure-1455-end-panels/dp/1414993 ]1455CAL-10[/url]. They have it listed on Farnells but at £15 seems a bit steep if you only need a couple.
Would it be possible to cut a replacement panel from the section you'd already cut off?
I thought earlier that if I'm using one of my gun batteries I might as well use the [url= 
]POUCH[/url] it goes in too which will save me about £25 all in 😀
troutie - how much you looking for the kit O xpe?
I call first dibs if its still going?
Love Tubs - MemberSlightly off on a tanget....
HOW addictive is this DIY LED thing?
Very! I have about 9 or ten different led lights now
Not long got in from a nightride with Troutie. He had one of these lights strapped to his head to see how it performed. Non of you will be dissapointed with this light, its compact unbelievably bright, fairly easy to build and the buzz factor hitting the trails from a light you have built from scratch. And also extremely adaptable to be run from more than one type and size of battery. Oh it also only just got slightly warm all evening.
Markyg82
Leds are .50 p cheaper each every thing else is the same
so yours on the dibbs rule if you want them .
I have just been out with smudge for a pootle aroung Ilkley moors and used the light on my helmet and was very impressed with its punch .
Edit Beat me to it Smudge .
I got hotter than the light .
it was hotting up when we stopped at those rocks but switched to low sorted that .
Wow, even more anxious now - thanks chaps!
Troutie, could you let me know what length you cut your hammond case down to (assuming the battery is external) as whilst I'm at my folks I'd like to cut it down.
Smudge have you heard about the panasonic nnp 3.1ah 18650's? Do you know of they are protected?
http://www.rutronik.com/index.php?id=59&L=0&tx_ttnews [tt_news]=2697&tx_ttnews[backPid]=120&no_cache=1
Money sent Mr Trout.
Where is the best place to get double sided velcro from?
Hi Jazid,
I doubt very much the cell will be protected but to get that Ah into the standard sized 18650 can will reduce its cycle life by a fair ammount and also be pretty expensive to buy.
Not sure on double sided velcro however you can get velcro straps like [url= http://www.karlu.com/product_info.php?currency=GBP&products_id=11417 ]THIS[/url] & [url= http://www.choiceful.com/disprod.php?pId=18487 ]THIS[/url].
What did you want to use it for?
Troutie - Ill have the xpe kit then. Email on the way re payment.
More Li-Ion battery holders available in the US [url= http://www.luminousdiy.com/Light%20Kits%20and%20Parts.htm#holders ]here[/url], with relevant thread [url= http://www.candlepowerforums.com/vb/showthread.php?t=240838&page=3 ]here
[/url]The battery holder provided as part of the bike light kit looks quite sweet;
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I have also found this [url= http://www.hoffmanamps.com/MyStore/perlshop.cgi?ACTION=enter&template&thispage=BikeLights&ORDER_ID=!ORDERID! ]site[/url] which may be of interest, again in the US.
Just heard back from TurboFerret and he's working outside of the UK which is why he stopped production, which is a [url= http://endless-sphere.com/forums/viewtopic.php?f=14&t=8660&start=30 ]shame[/url]
On Citizen Kanes original he used the Cateye [url= http://www.zyro.co.uk/brand/CATEYE/Light-x0020-Spares/id/CA5341831.aspx ]HELMET[/url] mount however this requires a seperate [url= http://www.cateye.com/store/parts.php?cid=2_25 ]SPACER[/url] (partcode 533-8730). I cant find this to buy in the UK and on the US site says it cannot send to UK? I've emailed Zyro to see what they have to say.
I've had a trawl looking for other options however they all seem to require some sort of base plate. What are people thinking of using for helmet and bars?
What did you want to use it for?
I got some with my mukcy nutz mudguard and it works a treat holding things around things - I think that makes sense.
It would be ideal for my bastid and for this project for holding stuff in place.
How about [url= http://www.chainreactioncycles.com/Models.aspx?ModelID=21993 ]THIS[/url]?
Perfect and cheap, which makes it even more perfect.
http://www.chainreactioncycles.com/Models.aspx?ModelID=7379
Any magic that can be done with this?
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Although it can take a 10w bulb - I guess it won't allow a led adequate cooling.
Jazid .
Probably too late now but I cut the last one down to 55 mm but 60 mm does give a bit more room and area for cooling .
Hi all, I've posted this question at the end of the Lumi to LED thread, not sure if it was the right place,Sooooooooooooo.....
with two 20mm triple optics, are you connecting the 2x3LEDs together in series, SP or just parallel? Does it actually make a difference considering the 'Solid State' nature of the technology?
Cheers
How about this for a battery bag?
http://www.focalprice.com/CS270B/Portable_Carrying_Pouch_25_Hard_Drive_Disk_Case_Black.html
battery bags? i just gaffa tape mine to teh top tube!
What about these jazid...was gonna suggest for a larf, but actually they seem very good..
[url= http://www.esky-heli.com/li-polymer-battery-safe-charging-bag-silver-p-7811.html ]http://www.esky-heli.com/li-polymer-battery-safe-charging-bag-silver-p-7811.html[/url]
Jeepers watch the vid attached to that page...i have an image now of flying down a rock garden, back pack on fire..
@NockMeister:
LOL
A LiPo battery and that bag are a "Wacky Races for MTBing" kit - just think of the competitive advantage you'll gain with leaving behind such a toxic smoke screen! The only thing missing would be that Mutley s****.
In the video, he flips the bag over to reveal a brown hole in the back of the bag from a previous test, so its not for use in a Camelbak then. "NOW 75% off!" - I can see why.
8xAAs don't seem all that bad after all :/
p.s. Mutley s**** could be added with one of [url= http://www.bigdawgspromo.com/index.php?currency=USD ]these[/url]
PSA - Maplins have hybrid AAs on offer currently. Picked some up today for this project.
Mark posted the XPEs today first class so you may have them tomorrow .
Could someone simpliy the wonderfully complex world of battery pack options for this project, assuming an external pack and aiming for say 3 hours life. Whats on offer out there? I'm getting a bit lost in all the flood of info, and im not at all familiar with the battery terminology (no idea what an 18650 is or why "protected" matters). Appreciate a simplified guide if someone has the patience.
18650 = big AA battery 3.7volt similar capacities
Protected cell = small electronic circuit stopping it over charging or dropping too low in voltage through use.
I think!!!
I'm going for AAs to start with as they are easy to get hold of and simple to understand.
Most AA rechargables are 2000mAh or there abouts. This is the capacity of energy. They are 1.2v. connect 2 in series and you get 2.4v. Connect 8 in series to get 9.6v still with a 2000mAh capacity.
If my memory serves me right the power draw of the 2 led's and driver is about 7.5w (watts). to get the power of the battery you multiply the volts and amps 9.6 x 2 = 19.2wh.
divide that by the 7.5w to get the run time.
If you can follow that then you can see that increasing the voltage and/or capacity incrreases the run time.
You need a minimum of about 7.5v to put through the driver though.
Confused yet? 🙂
ok if building it as the spec using BCT`s driver we have 2 leds wired in series needing around 6.6 volts his driver needs 1 volt so 7.6 volts are needed 2 18650 li ions will be 8.4 volts off the charger and slowly lose their voltage and the driver will go out of regulation and the leds will be driven straight from the remaining volts and dim somewhat
on hi I have tested this config and it gave 1 hour 30 ish mins before the light went out .
so the sweet battery would be 3 18650 cells in series to give nominal 11.1 volts this will run the light untill the cells cut out and have full power for the duration .
Protected cells have a circuit to prevent over charge and discharge which is harmfull to Li IONs .
not sure what the ceiling is in Stevens driver but you can use a 14.8 volt pack like a Lumicycle battery so you can use a wide variety of packs upto around 20 volts I have used my Makita drill battery and that is 21 volts when fully charged .
Here is a good site to learn about Li Ions
http://www.batteryuniversity.com/partone-5.htm
You have a 3S battery dont you Troutie? I'll post the charger up to you tomorrow 😉
Sorry for dropping in and out of discussions on here at the moment - I've been away for the weekend then have been fixing a carpet for SWMBO tonight and collecting the cats on the way back, meaning I've only just got in!
Unfortunately there was a problem with the Rapid order on Friday so it's only just been despatched to me today, should be able to start mailing kits out tomorrow.
For those who have made special requests, I will reply when I get the chance.
To quickly cover the battery topic, the driver ideally needs about 8.5V to be able to give full output and run comfortably within limits. If you are attaching it to the case to give extra cooling them that allows you to drop the voltage below 8V. The upper limit is 24V.
In general, the higher the better. Efficiency is usually higher and less current is drawn from the battery so less stress is being put on it.
If using 'standard' NiMH rechargeables I'd suggest the type that hold their charge such as GP Recyko or Sanyo Enloop. They are slightly more expensive but you don't need to worry about charging them up just before you go out as they don't lose their charge quickly unlike most other NiMH cells. AAs tend to be the best for price / capacity / size. Eight would give you 9.6V nominal and up to 25Wh of power based on the capacity of the cells you choose. This will give over 3 hours at full power, about twice that at half power. Take care choosing a holder, many of the cheaper ones you buy don't retain the cells all that well. If you don't mind losing the ability to charge them in a standard charger you can make up a battery pack and buy multicell chargers that do the whole pack in one go. You could also use a RC car battery pack, I believe the 9.6V ones tend to use AA cells.
Lithium cells have advantages, mainly the fact they can store more charge for their size and weight. People often refer to 18650 cells - these are similar to AA but a little bit larger. You can get 14505 cells which are the equivalent to AA size and could be used in an AA battery holder. Three lithium cells in series would give 11.1V nominal and protected cells would cut out at around 8.1V. I believe that to quick-charge lithium cells you need a special charger which monitors each cell individually.
Hi BCT,
My payment to you still says unclaimed in paypal. I'm just wondering if you received it ok?
I'm waiting until the items are ready to despatch before claiming payments. I've not forgotten!
Thanks BCT.
Quick question about the recommendation of gp or enloops. Are these better because they exhibit less of a voltage drop curve (which is very good in this situation where we have a V. cutoff) or that they just retain their charge better (the main benefit between charging and first use, asuuming you are charging before use).
If the latter then as enloops only have a maximum capacity of 2100mah, so surely a set of std nimh 2900mah (non enloop) technology would be better and last longer?
Question about 2.9ah std nimh vs 2.0ah hybrids still stands (I.e. Does greater capacity more than compensate for increased voltage drop?)
However I've just been reading on t'web and if I've understood correctly the eneloops have a lower internal resistance which results in less of a voltage drop during usage (which is good)
Review of eneloops and another interesting 1.8v 2500mah chunky AA here:
http://www.tomsguide.com/us/rechargeable-batteries-cell,review-1525-3.html
[url= http://www.amazon.com/review/RQFY1NUK4L58V/ref=cm_cr_pr_viewpnt#RQFY1NUK4L58V ]Showdown: PowerGenix NiZn vs. SANYO eneloop NiMH[/url]
I've found that 'standard' NiMH cells can lose a lot of charge fairly quickly. The Uniross ones I used in my digital camera are next to useless 3-4 weeks after coming off the charger.
If you are disciplined enough to put your light on charge before you need it then you are likely to do better with higher capacity cells. If you want a light you can just pick up and not have to worry about charging it beforehand then Eneloop or Recyko+ would be best.
NiMHs have a low enough resistance anyway that you won't need to worry about it. Current drain will be of the order of C/3 which is no strain at all - in RC applications you can get peak drains of many times C.
Anyone know where we are with delivery times on the parts? (not trying to hurry you guys just trying to reign in my excitment!)
Hoping to get the first ones out tonight provided I can kick some life in to my printer which has started missing bits out.
One problem, Rapid have let me down on the switches. I only have 22 and the other 25 I'd ordered they have given to someone else and more aren't due until December... I'm working on an alternative but the last few orders may be delayed slightly while I find something...
so, if i was going to make up a pack of say 8 or 10 Eneloop NiHM AA, where do I get the best multicharger suitable for that ?
not sure which way im going to go yet but thinking about making a pack for the completeness of the whole project as a diy. its either that or a smudge special i think.
BCT: were you posting your parts to the individuals or over to Trout to mail out with the optics?
BlackCatTech i can pick up a switch from maplin, send mine without and let someone else have mine!
the leds may be here by the end of the week so will endevour to get my stuff into Pats van asap .
and as I am currently nearly buried under a pile of wires will chuck in a few stray bits in each packet .
I think Steven is mailing the other stuff direct
Here is a little light i have made for a customers young un
[IMG] 
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[IMG] 
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got another to do when I get another driver from BCT .
I was going to ask about what sort of cable we should use in these lights!
Cheers for the heasd up trout, gives me some more time to try and source a bracket for the bars and helmet. I tried to get a couple of the spacers used by Ctizen Kane for the catyeye mounts howver Zyro have told me these are now no unavailable in the uk and they cant order them from the states 🙁 Back to the drawing board I go...
Mini light looks really nice, I'm very envious of you having the craft to be able to do this sort of thing so well.
Trout.
Nice one, looks interesting.
I like the lens cap, I like the look of those screws set around the edge like that.
🙂
Cheers Lumi does look very mini dive light .
Bastard M2`s broke a 1.6 mmm drill in one hole but after an hour managed to unscrew the sod .though did think about leaving it and gluing in a screw head .
tis a cracking little light half of one of these CKs
Curly as I found 2 whole reels of the cable in the pics in a skip .
I will throw in 1 metre to each Diyer.
He'll be pleased with those Troutie 8)
Don't go showing too much though or you'll be snowed under with those as well 😆
Thanks Troutie - the single LED is looking good - out of interest though does the cable terminate with a male or female end?
Good question steve
Female on the light so heres hoping you have a male on the batterys
yes - male on the batterries - just wanted to check!
Don't panic me like that!
Update on leds and stuff
I have got the vagina reflectors today
the leds are now in Stuttgard or were at 01.50 this morning .
I also have a bit of a problem .
not enough addresses .
so please could you all send me an address which matches your name and stw name .
you weren't the only one panicking- a mate was "showing off" his bastid and I saw they had the female plug on the battery - I obviously worry too much!
trout
Have mailed you with my address, looking forward to my little packets of joy falling through the door 🙂 If Maplins would pull there finger out with delivery that would be even better.
I have couple of questions about the assembley of the light.
You mentioned using 3/4mm screw taps, where would be the best place to get these and also the screw etc from?
Does it matter what silicon you use or does it have to be a specific type?
What glue would you recommend using, does this have to be a specifc type?
Last but not least any suggestions on mounts at all?
Aldi or Lidl sometimes have some cheap Tap and Die sets, or try Machine Mart.
The lumicycle mount looks good, or there is a cheaper Halfords alternative, the Electron mount is available on Ebay.
I have found that RC shops can be good for purchasing smaller diameter screws, in low quantities.
As for the taps. I use a local Hardware store which still sells taps seperately.
If you can't get to such a store, try your local Engineering merchants.
Failing that, you'll have to pick up a small set of taps, which may come with dies, then yeah, Machine Mart, etc.
If you do have to buy a small set, at least you'll have'm around, should you choose to undertake another project....
😉
I hope you lot are going to post Pics of your new lights.
I want to see them.
🙂
If any of the no-addresses turn into no-sales let us know, I'll snaffle a leftover set.
I have got the vagina reflectors today
Wow - are these going to cost more 😉
There are hundreds of brackets out there but its been attaching them to the light that has been puzzling me.
Im thinking of either [url= http://kaidomain.com/ProductDetails.aspx?ProductId=5611 ]MOUNT 1[/url] or [url= http://ant-supplies.co.uk/BicycleTorchMounts.aspx ]MOUNT 2[/url] and removing the section that would hold the torch body. The flat part that remains could then be screwed or glued to the bottom of the Hammond box.
Just a quick question. How much sinking is required for these at full? having looked at the ape parts that trouble sent, it seems a very small light can be made. I'm thinking external battery and inline switch. so only reflectors, leds and driver inside.
Ref the mount.
Surely this:
[url] http://www.chainreactioncycles.com/Models.aspx?ModelID=12871 [/url]
Can be used ?.
Remove the bar section, and use a washer and the nut.
Drill a hole in the underside of your light (assuming you've cut the hammond box into two parts to make two seperate lights) towards the rear of the light where your switches will be.
Then, before you close the box by screwing on the end plate, you hold a nut and washer inside the box, then from the outside you screw through the clamp into the nut.
Would this not work ?.
Then apply a little thread-lock and maybe a bit of epoxy around the washer to stop the light rotating, and I'd hope you're good to go.
Close the light up by attaching the end plate and I'd of thought that would be that.
Caveat: As I'm not familiar with the box or the mount, I expect I could be completely wide of the mark.
Alternatively, would this be OTT ?.
[url] http://www.wiggle.co.uk/p/cycle/7/Lupine_Handlebar_Mount_25mm_for_Lamp_Unit/5360009560/ [/url]