D.I.Y. Headlamp Assembly
"Nothing is Carved in Stone" Directions

GET CREATIVE... MODIFY & IMPROVISE

STEP 2: PUT IT ALL TOGETHER

Plug in the charger and make sure the switch is set for Ni-CD if that is your battery type. This ensures that the charger will shut off after 5 hours. If you start charging now, you can test your handy-work several hours after you finish this project.

I began by disassembling the headlamp as purchased. Yours may be different. I removed the straps, unscrewed the swivel mount, and disconnected the connecting wire from the included AA battery pack. I then spliced the Remote Control Car Connector Repair to the existing headlamp wire, using the butt connectors and the wire crimping tool. Real electronic wizards will solder all of the connections (much more reliable and sturdier contacts). I opted for the lazy man's method. Other headlamp assemblies may be easier to solder than splice.

Next you must create a holder for the battery pack. I decided on the traditional water bottle method. Explore your options: bag under seat (more wire), handlebar bag (drop bars only), strapped to your machine gun turret (just kidding), or any other method you see fit. At this point I busted out my trusty Dremel tool. I used the Dremel to chop the nipple off the water bottle. You may drill or you may cut... whatever you need in order to make a whole large enough for the battery plug to protrude from the bottle. Regardless of how you approach this step, proceed with caution. If necessary, get an adult to help (or someone who is proficient with sharp, dangerous tools). If using a Dremel please wear eye protection to avoid flying plastic. You get the point - CAUTION!

I am not responsible if someone gets injured or otherwise punished from taking these directions. Do not try this at home. Not for the feeble minded or for underage consumption.

Next, I placed the battery in the bottle. I  have thought of other ways of doing this since, but the battery can not be flopping around loose in the bottle. I chose a borderline-trash couch pillow (it was in the closet.. hadn't used it in over a year) and removed some of its stuffing (refer to above disclaimer, especially if you don't own the pillow).
There are products on the market, in spray form, that would be excellent, hardening, weather-proof, foam filler for this purpose. They can be found at Marine supply, Auto Body Supply and perhaps some Hardware Stores.  I didn't have any handy. Sufficiently cushioned from bouncing about inside the bottle, I proceeded to seal the contents in the bottle. For this purpose I used a combination of vinyl, flame-retardant, electrical tape and a tube of silicone sealant. If the possibility of being out during inclement weather is there, this is an important point; all of the connections and the water bottle should be protected from the elements.

My next step was to mount the headlight to my handlebars. This is where your own planning and ingenuity come in. Your choice of headlamp assembly will determine your methods in this step. Swivel brackets, armatures, cycle-computer mounts, rubberized hose clamps, nylon clamps, wire harness clamps, reflector brackets, automotive fog lamp assemblies, outdoor lighting assemblies, or my method of the Camco Multi Clamp and halogen fog lamp are all valid, to be explored, options. I mounted mine to the right-center of my handlebar with the above mentioned clamp and a small strip of rubber underneath the clamp to allow for more precise positioning (without over-tightening).

After checking all of your connections, and that the battery is fully charged (the light goes out on the charger), it is time to test your handy-work. Hopefully it is dark at this point, as you will get a more accurate picture of the results... or a great fireworks show if wired incorrectly. This reminds me of another point: the negative side of the battery should be connecting to the negative side of your headlamp. If you are confused about this you should purchase an inline fuse and insert this between the battery and the headlamp. If you are still confused, and can't determine what amp fuse to put inline, I would suggest exploring the aforementioned manufacturers of such prepackaged headlight setups (or find an electronically minded friend or relative for help).

I am quite pleased with the results of this assembly. I am sure that I will be experimenting and upgrading in the future. For now, this headlight serves its purpose... and it was a lot cheaper ($39) than the $129 and up assemblies that I looked at.

 I welcome any comments and suggestions. Feel free to contact me.

Happy (and well-lit) trails!

• I have long since upgraded to a Jet Lites, single beam  headlamp set up. I have left these directions up for those who may be interested in dabbling with their own homemade set ups. This headlamp was helpful for being seen, but for seeing the road in winter commuting darkness I had to make the jump to a professionally assembled unit.
  

• Home mechanics may find my bicycle tool list helpful. 

ITEMS YOU WILL NEED FOR THIS ASSEMBLY: YOURS MAY BE DIFFERENT

TOOLS NEEDED (Must-Haves):

• Small Phillips head screwdriver

• Large Phillips head screwdriver

• Flat head Screwdriver

• Wire cutters / crimpers

• Safety Glasses / Goggles

• Hex Wrench for water bottle mounts

OTHER USEFUL TOOLS:
(not necessary)

• Dremel Tool

• Drill

• Soldering gun / solder

NECESSARY ITEMS:

• Wiring connectors (butt connectors)

• Electrical Tape

• Silicone sealant (tube)

• Water Bottle

• Water Bottle Cage

• Flashlight head, Headlamp
  or Fog Lamp

• Mounting Hardware / clamps, swivel brackets, etc.

• Battery & Charger

• Battery Pack Connector Repair

• Primary wire

USEFUL ITEMS:
(not necessary)

• Replacement bulbs

• Inline fuse assembly

• Spray foam filler, somebody's old pillow or similar light packing.

• Solder

• Spare battery

• Spare water bottle

• Darkness (may belong in the necessary list)

My complete cost for this headlight assembly (excluding tax, tools and connectors I already had) was:

 $39.42

Not bad when you compare it to the available store-bought options. So far this headlight has performed flawlessly and is brighter and lights further than any in my previous experience.