DIY Headlamp

[tommy d]

I searched this forum, but couldn't find anything on DIY headlamps. Has anybody built their own headlamp? I realize that modern, commercial headlamps are pretty light, with good run times and other features, but there might be some interest by the DIY backpacking crowd.

I stumbled across this guy's website. He has a video and directions with pictures on making a $2 headlamp.

http://www.pcbheaven.com/projectpages/Portable_LED_Head_Light/

I can't help but wonder how this concept could be modified by the UL crowd. Any thoughts or ideas?

[Stuart R]

I made this a few years ago. It uses a 1 Watt LED powered by a single Lithium AA using a boost regulator circuit. The main box is 2.5" x 1.7" x 0.9". Total weight including battery is 2.5oz (70g). Cost of parts was considerably more than $2.

[Andy Duncan]

I made this one out of two small LED lights and a headband. It works great and is bright enough for around camp, although it's barely enough for night hiking on a trail. I got caught at night coming down from Vogelsang this summer and the batteries died just as I made it to Merced Lake. W/ new batteries it would probably be ok. Here's a link if you're interested in the details:

half ounce headlamp

[Steven Evans]

Very nice work guys. I made one earlier this year that came in at 13 grams.

More info here: The O.R.B.

[Henk Smees]

Very light: 4.5 grams (≈ 0.16 oz.).

The clothespin is used to show it works.

No secrets – stupidly simple:

[Steven Evans]

…easily converted into one.

I like the simplicity of that. Looks like you coated the assembly with some liquid rubber type stuff? Does it stay on when pressed, or just when you hold it down?

[Henk Smees]

Hi Steve.

I’m a great fan of “stupidly” simple items (fewer things that can go wrong). The idea isn’t mine — I used Rainmaker’s instructions. http://www.trailquest.net/TQaltgear.html#LED

There are several "encapsulation" ideas on Rainmaker's site. I used Method #2 first and afterwards dipped the whole thing in a kind of rubbery paint (thinned it a little). I don’t know the word but it’s used for waterproofing roofs. After letting drip down the excessive paint I only had to wipe off the LED “bulb”. If you go this route, make sure to use as little of the tape as possible; if you use too much, it will either show the wrinkles, or you need too much paint (both -too much tape and too much paint- will unnecessarily increase the weight).

It would be a bit more complicated to turn it into a headlamp because, as you mentioned, it doesn’t stay on if you don’t hold it down -I think you already supposed so-. This is my back-up lamp. My primary one is a Photon Freedom Micro, sewn to my hat (already posted some pictures of the way it’s attached — could repeat if required). If you’d want the light to stay on, have a look at this (no doubt it will be “a lot” heavier): http://www.instructables.com/id/Make-A-Mini-LED-Light/

[Bob Gross]

Stuart, what chip did you use in that circuit? I've looked through that manufacturer's data sheets, and I can't find anything that matches.

–B.G.–

[Stuart R]

Hi Bob
It's a LTC3490

[Bob Gross]

Very interesting.

The bare chip costs $4 now, so I don't know if it would be worth my trouble to build one. I could probably do a printed circuit board in one square inch.

–B.G.–

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