DIY Mega Head Flashlight With 6x10W LEDs

This is my new head flashlight. I know it looks a bit strange, but it shines as much as the lights in the car. I installed 6 LEDs each with 10W. All powered from a 14.4v battery from a cordless drill. This is the most powerful flashlight I have had in my entire life. To build this flashlight I used the previous project (DIY LED lights panel for 5$ - Cheap and Easy 6 x 10W) where I step-by-step described how to do it.

See more: DIY mega head flashlight with 6x10W LEDs

Step 1: Components

Components for this project

• Helmet

• Plastic box for electronics

• Some wires

• LED lights panel for 5$

Step 2: Measuring and cutting

I measured and cut the plexiglass board for electronic circuits. For cutting, I used a hot wire foam cutter from the previous project. Follow this link to see how I built this tool.

Step 3: Grinding the edges

After cutting the plexiglass, the edges are not smooth, that is why I am sanding them.

Step 4: Drilling holes

Now I can fit plexiglass into a plastic box and drill the mounting holes.

Step 5: Mounting LM2596

Time to mount the LM2596. LM2596 is a step down converter and I use this as the LED driver. In addition, I added a rectifier diode, this protects against reverse polarity.

Step 5: Adjust the current on LM2596

Adjust the current on LM2596. Just now I set the current at 0.5A, it is only for testing. I use a screwdriver to set the correct current.

Step 6: Putting everything together

Now I can put everything together and test how it works.