Wiring and Attachment of the Helmet Lamp

Cut a 14x8 mm opening for switch.  An Exacto knife works good for these square openings. 

The pivot can be made using 2 4 mm dia.x 10 mm   pan head screws, with lock nuts. 

Lamp can be fastened to helmet with VELCRO ® brand One-Wrap (20 mm wide x 270 mm long) with a 23 x 3.5 mm slot cut in the side.  It would be best to make the lamp to be able to break free easily in case of a crash.   You do not want the light impair the function of the helmet.   Part of the strap could be compromised with a cut so that it easily breaks free with minimal loading. 

The lamp is shown here with 10 NiMh AA batteries using a 5.5 x 2.1 extension cord with a 9V battery terminal clip. 

Materials:

2x 50mm Tubing.    < 2 €

1 x mr 16 5 W 12V LED order from me 34 €.

Halogen Lamp socket with leads:  2.10 - 2.80 Euro

mini toggle switch with solder connections Conrad 700039  2.23 Euro (need to cut square opening 8.5 mm x 14.5 mm)

10mm long shrink tubing, one piece for each solder joint.

1 pc..  5 mm diameter x 5.5 - 6 mm long.

Go to the specific Tube Lamp designs

[Lamp with Separate Battery]  [Helmet Lamp] [Tail light]