Ideas on building a custom headlamp?

Flashlight Modding and DIY Parts
1

I want to build one with a separate battery pack for long runtimes.
Would like to use something like this:
battery pack

and need to find either a generic LED module or housing with a heatsink that can be easily modified to insert a driver and LED.
Would likely use on a gopro or similar mount on a helmet.
something like this may be suitable, but I have no idea what size driver it would take inside, would likely like to put a module inside that can put out at least 2-3000 lumens on high power mode.
light module
If anyone else can find a better module or some sort of host, that would be great.
Something that fits a 17mm or 22mm driver would be perfect.

3

Sorry, i had no idea it was going to do that when pasting the link.
Its fixed now.

4

Won’t get 3000lm for a long time before the light steps down to protect itself.

There was a thread on here or CPF of a guy who made a remote battery for a zebra light headlamp.

Buy a single cell headlamp that has the modes/brightness you want, and a parallel cell holder. Drill out a hole in the tailcap to accept the cable from the battery bank and connect the wires to the correct parts of your headlamp.

If you can get a spare tail cap and make a removable spacer to inside the body of the light for the connections, you can always just run it as normal with a single cell.

5

Sorry, I should point out that I’m wanting to use this underground, not for cycling.

A group of us explore mines underground and this would be the main use. Many of the headlamps on the market only take 1 or 2 cells and don’t have the greatest runtime on high power.

3000 lumens would only be needed for boost mode when taking photos, etc.
I think around 1000 lumens for general use would be fine.

6

Gravel monkeys suggestion is actually not that bad, if I was to go with that, I think a right angled light would be not a bad option, since it can clip on front of the helmet much easier, or else you would need to mount on the side if the helmet.

7

Managed to find the guy (user called GeoBruin) who inspired this suggestion, it’s on the other forum but should show up if you google “Cave Exploring Headlamp List - regularly updated, includes tech specs” and scroll to post #90.

It’s a very slick modification, I’m surprised we don’t see more of these. If you do go down this route, take some photos and post them here!

Cheers,

gm

8

ThruNite TH30 and T shape Acebeam H30

9

I explore caves and mines here in the UK, I started with a Xtar H3 and its still going strong but now it is my backup light. Now I just use a Lumintop EDC18 and fabricated a small clamp to hold it to my helmet, I also bring a few spare cells for the safety aspect ofcourse but I only need to change them on big cave systems (6hours plus), it’s a great light. The good thing is that if you learn to use less light in a system the less reliant you are on runtime plus you save weight and space which can make all the difference on a long trip especially with SRT or ladders. I do have an Acebeam X45 for photos but some chambers are huge but looking back I wouldn’t have bought it if I done some more research as similar lights can be had for less. 1000 lumens is plenty for general underground exploration and many lights can do this with ease but you will always suffer runtime issues with one cell, ofcourse 21700 would be better but then you have to weigh up weight etc. I also carry my Acebeam for extra light as it is enjoyable lighting big areas now and then when it can be done in nice walking passages.

Good luck with what you go with

10

I have just built 2 caving lights with similar spec (dual beam, 2000lm max) that you may copy (see below).

Take into consideration that 6*18650 are very heavy on the head

11

Yes quite true.
Im actually building this one for a mate who wants one with a battery back on the belt. Personally I dont see the need, but he wants one with plenty of hours runtime.

The EDC18 is a nice light and I have been looking at getting one some time back for EDC use and an all round light when tramping.

I think 1000 lumens is plenty for general exploration, but at times there are huge stopes or other large cavities that we were struggling to light up to the top with all our lights combined, so having the extra brightness when you need it is always handy.

I had been looking at this bike light here. I have no idea if i could install a regular 17mm or 22mm driver inside or not without getting one in my hands first, but I can easily machine a pill if needbe, i guess the biggest issue is getting the right optic for it.
bike lamp

12

Yes I agree, some passages are huge. Even my Acebeam X45 won’t fully light them but it does do an incredible job. All the best