REI Headlamp Luxeon Star Mod

 
 
 
Luxeon Star
         

This great mod was completed and submitted by Randy D. M. Here is the process in his own words:

I took an REI headlight and installed a Luxeon Star into the case. I discarded all the original bulb socket, and enlarged the reflector opening to accept the Star when screwed 2/3 way down.

The original switch was the type when reflector is screwed down into place, a small ring surrounding reflector pushes a switch. Since that was all trash, I used a micro DPDT radio shack switch mounted so that it pokes out of the back of the reflector.
I used epoxy to mount the Star (with the addition of a copper penny in addition to the factory heatsink plate), the micro-puck and DPDT switch to the headlight case.
The beauty of the original battery pack wiring, is that it was using 4AA to produce 3VDC (two pair in series). Where the beauty is, you can choose
to use either 2 or 4AA to light it. Since I hadn't soldered in years, I chose to use the micro-puck (http://www.ledsupply.com/ledsupply/index.html)
for the power unit. This supplies the needed 3.6~4.0VDC to run the Star at optimum output and will squeeze the last bit of power from the AA's. The
output simply blows away the original 3vdc filament bulb and should give about 10 times the battery life.

Thanks to Randy D. M. for sharing this mod with FlashlightReviews.com and its visitors!

 

 
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