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ArcticMyst Security by Avery

DIY 100 Watt Halogen Flashlight UPDATED

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Update: See post 25 for parts list

So I was looking for a project to do, and decided to build a WL torch like flashlight.

Planning:
So I decided a Maglite would be the best host, so after hours on end of research, I came to the conclusion that a the lowest voltage for a 100 watt bulb with a reflector built in was 12 volts.

So that ruled out using a Maglite 6d with 6 NiMh cells wouldn't work (7.2 volts) and the only way to do it with NiMh was a Maglite 5d with 1/2d batteries.

The best price I could find 1/2ds for was $6 each, too expensive, I can have a WL torch cheaper.

So then I looked for 32600s for a 3d flashlight, but that totaled about the same.

So then I had an idea -- LiPo batteries. After some math, I found a rectangle battery that fits PERFECTLY inside with no rattle - 11.1 volts, a perfect voltage.

I didn't want to modify the maglite switch, so I bought a toggle switch with an nice blue LED, to take it's place.

I located a 12 volt 100 watt halogen flood bulb (I preferred a spot bulb, but couldn't find any), and then found a holder for the bulbs.

I also purchased a tempered heat resistant glass lens (the plastic one scared me with a halogen that powerful)

I am going to keep this info vague as I am considering selling these. EDIT: see post #25 for parts

Specs:

Wattage: 100 watts
Host: Maglite 6d
Run time: 20-30mins

Some notes on it:
The beam is shaped like an X as it exits the flashlight, making it perfect for burning

-------------------------------

So with that little but of info, here are some pics :D

Flashlight off
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Flashlight on
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4 pin charging connecter
attachment.php

On in the night sky, revealing the flood beam
attachment.php

Trees in moon light are ~60 feet away
attachment.php

Same pic, flashlight on :D
attachment.php
 
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Re: DIY 100 Watt Halogen Flashlight

thats awsome 6d are those even produced anymore?

EDIT: yes they are i was thinking of the 7D
 
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Re: DIY 100 Watt Halogen Flashlight

im interested what rectangle battery you used but since your planning on selling these.....:angel:
 
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Re: DIY 100 Watt Halogen Flashlight

Running a 12V lamp at 11.1V instead of 14.4V is a larger difference than you might think.
 
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Re: DIY 100 Watt Halogen Flashlight

Running a 12V lamp at 11.1V instead of 14.4V is a larger difference than you might think.

A LiPo peaks at 4.2 volts per cell, giving 12.6 volts total for the first part of the run, and 11.1 when drained.

Either way it is bright enough for me:beer:
 

ARG

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Re: DIY 100 Watt Halogen Flashlight

Is that the voltage monitor light on the front?

Do you have any more pictures of the reflector/head?

Awesome build!
 
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Re: DIY 100 Watt Halogen Flashlight

Is that the voltage monitor light on the front?

Do you have any more pictures of the reflector/head?

Awesome build!

No, it is just a blue LED on the switch, I looks cool, but dosent really serve a function, it is pretty obvious when the flashlight is on

I will post some more pics tomorrow.

Thanks!
 
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Re: DIY 100 Watt Halogen Flashlight

Hey would you mind posting links to all the places you found all this stuff? That would be quite helpful!
 

LaZeRz

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Re: DIY 100 Watt Halogen Flashlight

He said he's trying to be "vague" because he might sell these in the future ;)

If you want links to make a mag85 ( like "the torch" from wicked) then shoot me a PM :)
 
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Joined
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Re: DIY 100 Watt Halogen Flashlight

google mag85, m@g85, ROP.

Also, Jayrob sells a maglite kit.
 
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Re: DIY 100 Watt Halogen Flashlight

Sweet light! I would rep you but the rep system wont allow me :(
 

jayrob

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Re: DIY 100 Watt Halogen Flashlight

Nice job! :gj:



Here's links to parts and stuff for a similar build that I just did. It works great if you want to show off and light something on fire with a flashlight...

Using a 3D Maglite...



For a useful and awesome flashlight mod, see my 1000 lumen Maglite build here:
http://laserpointerforums.com/f64/f...ltage-monitor-parts-complete-light-59581.html



But for a build that will light fires like the WL Torch, here's the deal on an easy build that anybody can do for a burning flashlight that is better than the WL Torch...

The main reason I say it will be better, is the battery supply...

But I seriously doubt that the WL Torch, has the same quality switch and driver as the parts I show below...




You can use a 3D Maglite...

Note: Important to use the parts I show below for heat management:

The key is the heatsinking and switch to handle the heat, and what battery supply to use. It's best to get this custom switch: (I e-mailed him to check availability - Now available)
Mag D Incan Driver - Soft Start & Multi-Brightness

It has the heatsinking, ceramic socket, 3 modes, ready to go...

Then just use an aluminum reflector and a Borofloat glass lens to handle the heat. (52.1mm)

For a 3D host, you can fit 4 X IMR 26500's with a sleeve and tail cap mod! :D

Those will easily handle the current. So all that would be needed, is a sleeve for the 26500's... (I have fiberglass material for a perfect sleeve, and can do the tail cap mod if needed)

You'll need this charger:
Ultrafire WF-188 Charger for 14500 / 17500 / 18500 / 18650 / RCR123 3.7 volt Lithium Battery Charger

(don't buy that charger from a cheap source, or ebay, it most likely won't work properly)

Osram 64623 12 volt bulb:
OSRAM SYLVANIA EVA 64623 HLX 100w 12v GY6.35 Bipin Halogen light Bulb (order extra bulbs since they are cheap)

This is an easy build that you can do yourself with little effort...

The Borofloat glass lens, and the bulbs are cheap, but the rest of the parts are not so cheap.

Estimated cost in parts - $150 for the build, and then about $100 bucks for the 4 X 26500's, and the WF-188 charger...


Important: You just have to watch out that you do not over discharge the batteries. We're talking probably in the neighborhood of maybe 15 minutes max between charges... (probably less)
 

LaZeRz

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Re: DIY 100 Watt Halogen Flashlight

Btw Jay, have you found a cheaper source of ballasts? 75 dollars + shipping is a bit too high IMO. :D
 
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Re: DIY 100 Watt Halogen Flashlight

Thanks everyone for the nice comments :D

The reason I went with this design is that parts included, it totaled <$100, so if I sold them the price could compete with the WL torch

and I like big hosts
 

jayrob

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Re: DIY 100 Watt Halogen Flashlight

Btw Jay, have you found a cheaper source of ballasts? 75 dollars + shipping is a bit too high IMO. :D

I have not, but I have not looked though...

One thing I can tell you, this thing gets really hot, and fast. So I'm glad I have an all metal switch housing in there.

The driver that it comes with is a nice 3 mode driver, and it also has a ceramic mount for the 100 Watt bulb...
 




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