[at-l] One ounce LED headlamp

[kahley@ptd.net (kahley)]

Wow..what was the cost?

At 12:01 AM 6/28/02 -0400, Lamar Powell wrote:
>Tonight I finished making my head lamp but I had to fall in the floor and
>kick and scream because I had bought batteries that are 22mm diameter
>instead of the 20mm needed to fit in the holders I bought. It was quite a
>sight to see.
>
>Some time back somebody (Jan I think) recommended the Yahoo "make your
>own gear site" to me. I was intrigued by the one ounce headlamp made from
>quarter size 3.6v batteries and LEDs. The submitter ( James Alpigini)
>thinks the batteries will last 40+ hours. Well, I began looking at the
>local Radio Shacks and such places to see if I could find materials to
>make my own.
>
>I could not find 5600 mcd LED recommended so I've wired two 1100 mcd in
>parallel. Actually, I found the 5600 on the internet but by the time I
>paid shipping I could buy a Tekka. I'm taking a chance by using a smaller
>current reducing resistor. This could zap the LEDs right off or, at the
>least, shorten their usable life. Well, that's life on the edge. At my
>age, I need a 500w halogen to see clearly and the small resistor may
>allow the LED to be brighter................or they could just fry when I
>turn the switch on.
>
>I used some plexiglass as a mounting and glued the two battery holders,
>the resister and the two LEDs to it. I used a push on/off switch from an
>old mini flashlight as well as the protective lens. The case is a 35mm
>film can. By shear luck, the inside diameter of the can is such that the
>old flashlight would slide into it like it had been designed that way. I
>cut a .5 inch square hold into the can so the on/off switch can be
>mounted there. If the thing actually works, I'll use some bathtube
>silicone to weather proof the switch opening and the front lens. I cut
>off the bottom of the plastic film can and replaced it with the lens off
>the old flashlight.
>
>Once I see light actually coming out, I'll invest in a length of elastic
>which I'll attach to the film can top. This will become the handband. I
>don't know how much weight the elastic will add. Tonight I put the
>headlamp and the two incorrect size batteries on my little kitchen scale
>and it all totally up to just a smidgen under one ounce. My old trusty
>Petzl weighed 9 ounces.
>
>Ya'll wish me luck as I go back to Radio Shack to get the right size
>batteries. If this thing works, it would be a worthy project for folks
>looking to shave 8 more ounces (4 packs of tuna or 2 snicker bars) off
>their gear weight.  Hopeful
>
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