18650 battery case for low cost bicycle headlights

fabxyz · 2019-10-27T22:13:38.000Z

I constructed a 3D printable slim 18650 battery case that can be used with standard chinese 8V (2S) bicycle headlights. Thought some of you might be interested…

The case on thingiverse:

thingiverse.com

Bicycle light battery case by fabxyz

There are many cheap and very bright headlights on the market, but most of them come with a battery of poor quality. At the same time high quality 18650 Li-Ion cells are easily available and widely used, yet rarely found in form of separate cells in...

There are many cheap and very bright headlights on the market, but most of them come with a battery of poor quality. At the same time high quality 18650 Li-Ion cells are easily available and widely used, yet rarely found in form of separate cells in end user products. Here I present a battery case that allows to replace the cells on the go, which gives you the opportunity to easily carry energy for several nights, at very low cost. The use of protected cells is highly recommended, the cells can be taken out of the case and charged separately in a universal charger.
I provide a “package” of 3D-print parts (battery case, different case mounts), that can be assembled with some additional parts (battery connectors, cable, plug). Together with 18650cells, a charger and some headlight it builds a high end MTB light bundle.
The battery pack provides an output voltage of 6.4 to 8.4V. It has to be used with an appropriate headlight (most headlights with this connector work on this voltage).

Collection with GoPro adapters for Kaidomain lights:
https://www.thingiverse.com/fabxyz/collections/bicycle-light

EasyB · 2019-10-28T01:02:11.000Z

Cool, thanks for sharing. Definitely a useful item for the reasons you explained above.

I just soldered two 4000mAh 21700 cells to make a 2s pack for a handlebar light that I modded. This old light came with an SSC P7 LED. I put in a sliced XHP50 behind a ledil Iris TIR. Makes a nice beam.

Paul321 · 2019-10-28T12:17:35.000Z

fabxyz,
Nice job! thanks very much I will have a co-worker print this for me. I use a Thorfire bicycle light on my snowblower, the battery pack (no-name 4 cells) that came with it is not water resistant, this pack appears to be able to be made water resistant.

YuvalS · 2019-10-28T12:49:00.000Z

Nice job!
Have a look at this off the shelf aluminum case:
https://www.speleo-s.ru/BA2884.html (Russian link)