bike_sm.jpg (13051 bytes) Helmet Light

 

 

head_lamp.GIF (11362 bytes)helmet_lights.jpg (8346 bytes)

 

 

 

 

Housing Design 1:  Internal lamp retainer ring 

Note: Angle of cut might be dependent upon the helmet design.  This design uses 35º

head_lamp_1.GIF (8087 bytes)

Housing Design 2:  External lamp retainer ring

head_lamp_2.GIF (8049 bytes)

 

headlamp_wiring.jpg (11126 bytes)Wiring and Attachment of the Helmet Lamp

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

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. 
headlamp_battery.jpg (10899 bytes)

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:

tubes_sm.GIF (1308 bytes)1x 50mm Tubing.    < 1 €

 

 

led lamp_sm.jpg (3087 bytes)1 x mr 16 5 W 12V LED

 

 

582395_RB_00_FB_EPS.jpg (8895 bytes)Halogen Lamp socket with leads:  2.10 - 2.80 Euro

 

 


mini_switch_700039.jpg (7574 bytes)mini toggle switch with solder connections Conrad 700039  2.23 Euro (need to cut square opening 8.5 mm x 14.5 mm)

 

 

532525_BB_00_FB_EPS.jpg (2990 bytes)10mm long shrink tubing, one piece for each solder joint.

 

setscrew_sm.jpg (3430 bytes)1 pc..  5 mm diameter x 5.5 - 6 mm long.