Cheap 6 volt lighting system!!!

[Sgt. Howard]

Starting with the headlight- here's the donor system

Bought at Wally World for less than $10. 10 LEDs- does a good job of lighting up the road.

 

[Sgt. Howard]

Yes, I realize that 4 strokes do not have the 'white wire'- I'm not even sure the 2 strokes have them anymore... but the batteries are plentiful and easy to come by, and with LED operation they ought to last a good while. This particular flashlight comes apart easily and lends itself to many different housings- the one I am building here is a bit heavy, but will have it's own charm as you will see.

 

[Sgt. Howard]

Here we see the takedown- - I cut off the knob to reduce it further for my application. The red wire is positive hook-up, the tri-pod stand is negative.

 

[Sgt. Howard]

The Bezel is the component that hold the lens and reflector in the headlight body- I found a way to make them from flat brass... so easy I can't believe it! THIS is my first attempt, with a piece of pipe for an anvil and a large hose clamp and a hammer... I need to do it again so that I can show how. I now understand why brass was used in making headlights early on.

 

[wheelbender6]

Keep em coming Sarg. I have cobbled together 6v and 12v lighting systems with mixed results, so I'm interested in your approach.

 

[curtisfox]

This is KOOL, just like old school. Put a cpouple tabs on the seam and run a small bolt through for clamping. .....Curt.

 

[Sgt. Howard]

Creating a bezel from flat brass requires precise, specialized gear-

but you can do it with this

 

[Sgt. Howard]

"We don't need no stinkin' metal rollers!!!"- the process is started by hand.

 

[Sgt. Howard]

Adjust so that there is enough to cover were you want it to attach AND enough to hold the lens and reflector once it is bent.

 

[Sgt. Howard]

THIS is TOO MUCH overlap!!!

 

[Sgt. Howard]

Now everything is set, tighten the clamp as tight as you can and start slowly tapping the edge inward, going VERY slowly...

 

[Sgt. Howard]

Here is the old Sgt. showing how it is done

 

[Sgt. Howard]

Here is the finished product, on the pipe and off

 

[Sgt. Howard]

NOW- HERE is what I am mounting it on

 

[curtisfox]

So KOOL! What is the headlight bucket from?

Maybe post this in your build thread? It is part of your build?.............Curt

 

[Sgt. Howard]

Where it is so far

So KOOL! What is the headlight bucket from?

Maybe post this in your build thread? It is part of your build?.............Curt

The headlight body is the top cap for a 4" Cyclone fence post- ousted diameter is 4&1/4"

 

[Sgt. Howard]

Yes, I am aware of the gap- here is step 1... "THAT will look like rubbish!" I hear you say...

 

[Sgt. Howard]

HERE is step 2- "... oh... wow..."

 

[curtisfox]

LOL! KOOL and simple...........Curt

 

[Denis Zen]

Sweet bro!