Homemade flashlite

[Cronus97]

Hey all i am trying to make a list of every part i would need to turn an aircraft bullet shell into a rechargeable flash lite.  

a list of features I want

 

• Rechargable
• >200 lumen
• <$30 will go to 60
• waterproof?
• 4 hour continuous battery

 

This is a bit of a project and i have the skills to get it done, i'm just not familiar with the different types of LED's, and how rechargable batteries would fit in with the led and charger.

 

Dimensions

 

opening diameter = 30mm

height = 173mm with usable space of 160mm

from top opening to bullet shaft is 30mm

shaft diameter 44mm

 

References

http://www.superbrightleds.com/moreinfo/high-powered/vollong-5w-white-high-power-leds/898/

 

Pictures

[upliftsleet1974]

I want to see this....This could be good!!

[Hans Christian | Teri]

That's a pretty serious caliber. Interesting project.

[Cronus97]

Battery, http://www.amazon.com/3400mAh-PROTECTED-Orbtronic-Rechargeable-Battery/dp/B00ANX46H2

 

LED, http://dx.com/p/xm-lt60-1000lm-led-white-light-emitter-with-18mm-base-2-9-3-5v-54704 or

http://dx.com/p/3w-16mm-cree-p4-aluminum-pcb-board-with-warm-white-led-light-silver-122588

 

Charge Regulator, http://www.ebay.com/itm/DC-4-7-24V-2A-Charger-Module-For-3-6V-3-7V-500mAh-to-15000mAh-Lithium-Battery-/141155717844?pt=Battery_Chargers&hash=item20dd8952d4

 

Jack, http://www.ebay.com/itm/5-x-DC-Power-Jack-2-1mm-Panel-Mount-Bulkhead-Free-Shipping-/251152134807?pt=LH_DefaultDomain_0&hash=item3a79d57297

 

Driver Board?

 

And then my biggest problem, how am i going to secure the components on the inside, I could try cutting the bottom off and creating a thread, or I can bunde everything together with the charger and toggle button on the backside and stuff it in the top, and find a way to cap o

[Cronus97]

Reserved

[UtterTulip]

Looks nice

[Scheer]

Deal Extreme will be your best friend for a cheap DIY flashlight. http://dx.com/c/flashlights-lasers-999/flashlight-parts-and-tools-917

 

Are you going to somehow split the casing and have the primer end thread on and off, or just shove all the components in thru the neck and glue it? I'm assuming the latter as you want it rechargeable, but even the best batteries will die... so I would try to find a way to make the batteries replaceable.

 

For the charger you should be able to find something similar to this: http://www.ebay.com/itm/DC-4-7-24V-2A-Charger-Module-For-3-6V-3-7V-500mAh-to-15000mAh-Lithium-Battery-/141155717844?pt=Battery_Chargers&hash=item20dd8952d4 that will fit in the casing, then use a panel mount DC jack like this: http://www.ebay.com/itm/5-x-DC-Power-Jack-2-1mm-Panel-Mount-Bulkhead-Free-Shipping-/251152134807?pt=LH_DefaultDomain_0&hash=item3a79d57297

 

Your best bet for a battery is going to be a 18650, rechargeable, Li-Ion at 3.7V, and is the most common I have seen used in flashlights.

 

If that is anything like a small arms caliber round then there should be plenty of brass at the primer end to have someone drill and thread it for a large brass plug that would contain your push switch and allow you access to the electronics. The switch would be in the center of the plug, so have two holes drilled on each side of the switch to use a spanner wrench to remove and install the plug.

 

[Cronus97]

Deal Extreme will be your best friend for a cheap DIY flashlight. http://dx.com/c/flashlights-lasers-999/flashlight-parts-and-tools-917

 

Are you going to somehow split the casing and have the primer end thread on and off, or just shove all the components in thru the neck and glue it? I'm assuming the latter as you want it rechargeable, but even the best batteries will die... so I would try to find a way to make the batteries replaceable.

 

For the charger you should be able to find something similar to this: http://www.ebay.com/itm/DC-4-7-24V-2A-Charger-Module-For-3-6V-3-7V-500mAh-to-15000mAh-Lithium-Battery-/141155717844?pt=Battery_Chargers&hash=item20dd8952d4 that will fit in the casing, then use a panel mount DC jack like this: http://www.ebay.com/itm/5-x-DC-Power-Jack-2-1mm-Panel-Mount-Bulkhead-Free-Shipping-/251152134807?pt=LH_DefaultDomain_0&hash=item3a79d57297

 

Your best bet for a battery is going to be a 18650, rechargeable, Li-Ion at 3.7V, and is the most common I have seen used in flashlights.

 

If that is anything like a small arms caliber round then there should be plenty of brass at the primer end to have someone drill and thread it for a large brass plug that would contain your push switch and allow you access to the electronics. The switch would be in the center of the plug, so have two holes drilled on each side of the switch to use a spanner wrench to remove and install the plug.

 

Thanks! Deal extreame has some very helpful components listed, im planning it on paper now. 

Battery, http://www.amazon.com/3400mAh-PROTECTED-Orbtronic-Rechargeable-Battery/dp/B00ANX46H2

 

LED, http://dx.com/p/xm-lt60-1000lm-led-white-light-emitter-with-18mm-base-2-9-3-5v-54704 or

http://dx.com/p/3w-16mm-cree-p4-aluminum-pcb-board-with-warm-white-led-light-silver-122588

 

Charge Regulator, http://www.ebay.com/itm/DC-4-7-24V-2A-Charger-Module-For-3-6V-3-7V-500mAh-to-15000mAh-Lithium-Battery-/141155717844?pt=Battery_Chargers&hash=item20dd8952d4

 

Jack, http://www.ebay.com/itm/5-x-DC-Power-Jack-2-1mm-Panel-Mount-Bulkhead-Free-Shipping-/251152134807?pt=LH_DefaultDomain_0&hash=item3a79d57297

 

Driver Board?

 

And then my biggest problem, how am i going to secure the components on the inside, I could try cutting the bottom off and creating a thread, or I can bunde everything together with the charger and toggle button on the backside and stuff it in the top, and find a way to cap off the top.