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I sent a payment to BCT last night using the email in his profile but paypal is saying its unclaimed?
You should be able to get my address by clicking the 'Member' link next to my username. I'm guessing posting it direct in the forum is an invitation to spammers...
I've not claimed payments yet, partly because I've been busy but also because I'm waiting for the parts to arrive.
Regarding batteries and battery life, the output power drain of the unit will be about 7.5W on full beam including the losses within the driver. Multiply the battery voltage by the capacity (amp-hours, if it is in mAh, divide by 1000) and that gives the power available in the battery. Divide this by 7.5 to get the approximate run time on full power.
It might be worth considering going for the type of batteries that keep their charge - standard NiMHs discharge fairly quickly once removed from the charger. Sanyo Enloop and Gp Recyko+ are two that have this property. You could make a nice little permanent pack and use a plug-in charger rather than having to remove the cells each time you want to charge them up. I find CPC (cpc.farnell.com) have a good range of chargers and batteries but you need to spend £45 with them to avoid a small order surcharge. Otherwise, I'm sure eBay will come up with something or Maplin if you don't mind paying their price premium.
(That said, I'm surprised that Maplin aren't that much more expensive than Rapid for the Hammond enclosure.)
I think I have found a new inspiration for my light housing!
Jazid - Classic! I wonder how many lumens you get from the average car headlight - beating that on a bike would be something..
One thing I've just remembered I was going to say, the driver in the photo Troutie posted is an old version, the terminal arrangement is different on the new ones. I'll be including a datasheet with them so take care to read that, not follow the picture!
Thanks for the runtime information, its all slowly starting to sink in and make sense.
At home I have some airsoft batteries which I think are around 8.4v. I'll check once I get home. They have a small white plug on them which look similar to [url= 
]THIS[/url]
FWIW I reckon it should be called the Citizen Kane or CK light.
Hows this the CKLuminator
so my 7.5 4300mah nimh will give 4hr runtime? sounds good to me!
it'll prob dim a bit but then if i'm riding 4hrs in the dark i recon i'll be fading too!
The "Rosebud" light?
Payment sent trout.
Paypal gift sent to both
Cheers Steve.
Paypal gift sent to both, hopefully for the right amounts 😉
So quick Q, will the driver be ok with 4 18650 cells ?
If so should I do 4 in series to ensure good voltage or would 2 sets of 2 in parallel i.e. 7.4 volts cover me, feels close to tolerance with around 3v drop per LED.
Final Q assuming I can use 18650, is there a reason people are opting for the AA's as the cheap (probably highly volatile) 18650 cells on eBay are around the same price 😉
Really looking forward to this project, great work by trouty and BCT in opening this up and giving so much support!!
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 😉
If so should I do 4 in series to ensure good voltage or would 2 sets of 2 in parallel i.e. 7.4 volts cover me, feels close to tolerance with around 3v drop per LED.
Final Q assuming I can use 18650, is there a reason people are opting for the AA's as the cheap (probably highly volatile) 18650 cells on eBay are around the same price
My thoughts too!
Good work guys. Need to do the BCT PP, it will come!
My reasons for using AA's was simply based on cost as this will only be a temporary pack until I can get a Li-on pack. It will cost roughly £20 to get the enclosures and batteries for two packs of ten cells and I already have a charger. Once I have the Li-on packs the AA's will disappear throughout the house in torches, Wii controlers and to appease the Battery Monster, a close relative of the Sock Monkey 😆
Alternatively I have two airsoft battery packs.
[IMG] 
[/IMG]
The large green one is 8.4v 3800mAh NiMH and the smaller red one is 8.4v 1300mAh NiMH.
Would these be better then the AA's?
Fozzyuk
the 4 x 18650s will be better as a series set the 14.8 volts is better than the 7.4 as the 7.4 will drop in voltage to the dropout zone .
the 14.8 volt will stay in regulation all the time until the batteries are depleted .
one question are the cells protected .
Stayhigh both your airsofts are good to go as well as the 10 cell AA packs .
I don't have the 18650 cells yet. I have two trustfire ones I've used since last year in the dxtreme mte torch, they were advertised as protected...
I also have a bastid, no idea if that packs protected., I think it's 4 18650.
If anyone knows of a safe 18650 brand let me know....
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
[img] 
[/img]
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;
[img] 
[/img]
[img] 
[/img]
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.