This mod/circuit is supplied in its entirety by Ned K. Thanks Ned!

Rayovac Headlamp Luxeon modification

This Luxeon modification uses my LT1308 voltage regulator.

I started with a Rayovac Kid's headlamp, which cost me $6 at the local Wal-Mart. This is a fairly well made, moderately weather-resistant headlamp that uses 2 AA cells and a small bi-pin bulb. It comes with an extra bulb.

I removed the little lamp clips and soldered wires directly to the metal strips:

I then removed all the protruding plastic pieces except the two posts that hold the semi-circular bulb mount. I drilled and tapped 2 4-40 holes for the Luxeon.

Then I attached a white Luxeon Star and my step-up regulator:

After that, I hot-melt glued the regulator to the underside of the bulb mount, put the bulb mount into the case, and screwed the Luxeon down.

Because there's no heat sinking here, I limited the current to 190mA. This will also help get better battery life.

I expanded the hole in the reflector so I could screw the cap down the whole way without hitting the Luxeon's leads.

Later, I removed the reflector and attached the collimator (lens assembly) from a Star/O. This improved the beam considerably.

In fact, you can do this mod with a Star/O; it just mounts a bit differently.

Many thanks to Ned K. for sharing this project with FlashlightReviews.com and its visitors!