A Low-cost Alternative to an Adjustable Headlight: Reuse Your Mini LED Flashlight

I had this idea to make my own simple headlight for use during treks. Being the DIYer that I am, I salvage any and every electronic goods. So lets start and learn how to build this simple head light.

1. PVC sheet [ We had some plumbing work ongoing, so had some leftover PVC tubing schedule 40 type 2.5mm thickness lying around]
2. Old flashlight [ No fancy flashlight needed, this one I used to have a faulty slider switch which powered a resistor-based LED circuit. it is 0.5W led and should provide ample light for a long time with continuous usage]
3. 1 AA battery holder for 2 batteries. [ The size of the AA battery holder should match the number of batteries ur flashlight was using.]
4. 2 AA alkaline batteries / Any batteries which your flashlight uses.
5. SPST switch [ SPDT Slide Switch buy online at Low Price in India - ElectronicsComp.com ]
6. Adjustible Head straps [ Usually headstraps for flashlights have 3 sides, so arrange likewise ]
7. Glue [ Instant or plastic which sticks to PVC ]
8. Drill bit [Any size which is suitable for ur requirement ]
9. Drill machine [Hand / Power ]
10. Wood pieces / Ply board or anything which can help bend PVC
11. Screws
12. Sandpaper [ 120 grit ]
13. Paint
14. hacksaw / cutter
15. Velcro straps

We will start off by searching for a simple flashlight. Mine had a mechanical slider switch which was not working properly. So, I sacrificed the body. If you see closely, I retained the part of the housing which allowed the front LED circuit and reflector part to screw on.

TIP: When cutting small objects using a hacksaw that are difficult to hold on to, drag the object across the blade and keep the blade stationary. Sort of how we use a curved knife with a wooden base that is used for chopping vegetables. We drag the veggies across the blade rather than moving the blade

Check that the flashlight LED is still working.

MAXIMUM ATTENTION NEEDED WHILE HEATING !!!

Cut your PVC tubing along the height of the cylinder and hold it over any heat source [ hair dryers work very slowly, avoid] which produces no soot.

Soot will make your PVC black so avoid sooty heat sources

After holding and continuously moving the PVC sheet back and forth over a flame / heat gun, you will notice the sheet becomes very pliable and starts to unfurl.

Place it on a flat surface [ your kitchen counter top maybe] and use a flat object [ a steel plate ] to press on

The aim in this step is to form 2 brackets.

1. The first bracket will be called the forehead support and battery mount bracket
2. The second bracket will be called the reflector mount bracket.

The first bracket will need a jig to be made in order to shape the bracket in one go.

The wooden jig will be a U channel with support to form flanges.

Cut PVC sheet to desired dimensions and heat to make it flex.

Press the sheet into the jig to shape it.

the second bracket is a simple C bracket to hold your reflector.

Pretty simple to form and needs no jig

Next we need to attach both bracket.

While bracket 1 will rest on your forehead, bracket 2 will hold the reflector.

use screws will less depth so that the screw tips sit flush with bracket 2

Make a small PVC piece to attach at the bottom to hold the batteries in place

All slots details in video link : https://youtu.be/oADAH3w9OYw

Bend the flanges to match the contour of your temple.

Attach rexin straps using super glue

I cut these straps from an old seat cover of my bike.

Before attaching velcro straps make sure to check the dimensions of your head.

In this we mount the SPST slide switch. Use super glue with baking soda to prevent the glue from jamming the switch.

Any switch can be used, I had this laying around.

Next we proceed to painting the assembly in a color of your choice.

Vibrant and easy to spot colours like ORANGE could be used. Iused black to match the strap colour