So I am planning on building a headlamp, hopefully I will finish it by February.
The body will be made of aluminum to double as heat-sink and the battery box will be made of some kind of plastic. both will be build using hand tools.
I want to print my own driver but I have no experience with printing circuits so maybe I will use a commercial driver and modify it.
As a FW I am planing to use my own code that is need some improvements.
Welcome to share your thoughts.
Yuval
EDIT: 29/02/2020
Just before the deadline, I wanted to thanks all BLF members that helped and encouraged me during the build and especially to the annual BLF/OL contest team that pushed me to build the light
I made a short video to summarize the process so people don't have to read the entire thread:
And here is pictures of the final result:
Evanualy, I did used some modified commercial driver and didn't print my own, maybe for the next year competition....
YuvalS's Hand Made Class, 7th Annual BLF/OL contest entry topic
Wed, 11/20/2019 - 07:55
#1
YuvalS's Hand Made Class, 7th Annual BLF/OL contest entry topic
Edited by: YuvalS on 02/29/2020 - 08:30
Sweet! Really looking forward to it.
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Sounds good, always nice to see a self built headlamp
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All the best for the build YuvalS.
djozz quotes, "it came with chinese lettering that is chinese to me".
"My man mousehole needs one too"
old4570 said "I'm not an expert , so don't suffer from any such technical restrictions".
Old-Lumens. Highly admired and cherished member of Budget Light Forum. 11.5.2011 - 20.12.16. RIP.
Thanks MRsDN, you too.
So today I made the preliminary sketch of the body.
I am planing to built it using 3 pieces of 6mm Aluminum glued together.
6mm Aluminum is easier to buy and easier to work with using the tools I have.
3*6mm = 18mm will give me enough space for a 17mm driver and 14mm optics + 2 mm mpcp (=16 mm)
My hand Made Class, 7th Annual BLF/OL contest entry
My modification Class, 8th Annual BLF/OL contest entry
Nice start
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So my GF travel to Germany for the weekend and I had an opportunity to take over the living room and convert it into a workshop

I started to build the body. Since it it made out of 3 pieces of aluminum I decide to first attach the 3 pieces together using screws. It will enable me to precisely drill the 2 mm drills for the screws around body.
I did not manage to use the drill press before the pieces are screwed together so I had to drill another set of drills by hand
I tapped M4 to the bottom aluminum piece
And now I screwed all pieces together and can continue working on body but I have to wait for the next time I will be able to conquer the living room
My hand Made Class, 7th Annual BLF/OL contest entry
My modification Class, 8th Annual BLF/OL contest entry
Good stuff. You may find it easier to tap the holes with a battery drill, it is easier to keep the tap straight. Use WD40 or something similar to lubricate it.
I have lubricant in this green plastic. I also use it for drullind and sawing but never thought of using a WD40, maight be easier to apply, THX
My hand Made Class, 7th Annual BLF/OL contest entry
My modification Class, 8th Annual BLF/OL contest entry
You are in so much trouble when your GF reads this thread YuvalS. Love your style.
djozz quotes, "it came with chinese lettering that is chinese to me".
"My man mousehole needs one too"
old4570 said "I'm not an expert , so don't suffer from any such technical restrictions".
Old-Lumens. Highly admired and cherished member of Budget Light Forum. 11.5.2011 - 20.12.16. RIP.
YuvalS Nice build. subscribed
Note: If you do not want oil on your projects, dish soap works just fine.
Think outside the box too long , cannot find your way back in.
Necessity is the mother of invention and the father is creativity.
Never give up, Never surrender. Make someone Smile today.
Good start
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Nice room conversion
Good to see you make a start
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My 7th Annual contest entry My 6th Annual contest entry My 5th Annual contest entry My 4th Annual contest entry
My DBSAR inspired SRK lantern hand made mod
After the progress yesterday I wanted to continue working on the body after work. Unfortunately my neighbors are not big fans of me building lights at night (TBH they are also not like it when I build other stuff)




luckily, I have found a 220v outlet next to the road around my neighborhood, far from any building and was able to work there
As you can see I have took CNCman advice about using dish soap as a lubricant since it is easier to use when working outdoors
It was quit challenging to drill 12 2mm holes in a 5mm border but I am quite happy with the result, no drill pierced the side of the body and I only broken one drill bit
My hand Made Class, 7th Annual BLF/OL contest entry
My modification Class, 8th Annual BLF/OL contest entry
Perfect combo of will and "do with what you have" spirit !
That’s dedication.
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What they said ^
Today I sawed the corners and turned the rectangle octagonal.


Unfortunately I forgot the jigsaw blade at home and the Dremel blade is too small, so I had to use a hand saw.
After sawing, I smoothed it all out using a file. The result is not perfect, but since it all done using only manual tools I am quite satisfied.
The body is finally take shape
My hand Made Class, 7th Annual BLF/OL contest entry
My modification Class, 8th Annual BLF/OL contest entry
You’re crazy mate
Couldn’t tell where you were this time
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Looks like good work under less than ideal conditions.
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My 7th Annual contest entry My 6th Annual contest entry My 5th Annual contest entry My 4th Annual contest entry
My DBSAR inspired SRK lantern hand made mod
Love the new workshop.
djozz quotes, "it came with chinese lettering that is chinese to me".
"My man mousehole needs one too"
old4570 said "I'm not an expert , so don't suffer from any such technical restrictions".
Old-Lumens. Highly admired and cherished member of Budget Light Forum. 11.5.2011 - 20.12.16. RIP.
Thanks guys, it is the same workshop as previous pictures .
Looks like I will not change this place unless someone will kik me from there.
I am also using this spot to work on my camper car conversion so it is a busy workshop
My hand Made Class, 7th Annual BLF/OL contest entry
My modification Class, 8th Annual BLF/OL contest entry
Back to the "Workshop" today for drilling the body using 27mm Holesaw to create some space for the optics and electronics
My hand Made Class, 7th Annual BLF/OL contest entry
My modification Class, 8th Annual BLF/OL contest entry
Looks nice so far.
I cannot see several pics in post #26.
How to Post Images on BLF // Many knives for sale (USA only)
How to move a thread
Looking good,
I once built a Datsun 180b engine in a kitchen in a flat in Melbourne.
sorry all images down
thanks photobucket
Same problem here
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My 7th Annual contest entry My 6th Annual contest entry My 5th Annual contest entry My 4th Annual contest entry
My DBSAR inspired SRK lantern hand made mod
Can I tell everyone what else you have done mechanically in houses?
djozz quotes, "it came with chinese lettering that is chinese to me".
"My man mousehole needs one too"
old4570 said "I'm not an expert , so don't suffer from any such technical restrictions".
Old-Lumens. Highly admired and cherished member of Budget Light Forum. 11.5.2011 - 20.12.16. RIP.
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