I made this to compliment my Tiger lights. Looks like this:-
The helmet is an ‘el cheapo’ Lidl one and the light is based on a LED Lenser H7 unit, probably the best ‘bang-per-buck’ headtorch out there. Costs under £35 and forget the 140 lumens spec; mine easily outperforms my mate’s 250 lumens one, as shown here. Mines on the left:-
Reason for this is that AAA have a much shorter between charges life. Longest I’ve ever seen in rechargeable is 1000mAh whereas AA go to over 2700mAh.
I just removed the elasticated headband, made a small bracket that is zip-tied to the helmet, cut away the old battery holder (this unfortunately disables the fader switch, but as mine was on full power all the time …..) and soldered the battery holder on it. This is held to the helmet top with a Velcro strap and has a bit of rubber (old bar grip) under it to keep it steady.
Whole lot including the helmet and batteries weighs just under 500gms and costs less than £40 – or about £50, including the helmet.
Gives the Hope Vision 1 a good run, being just as bright but with the ability to flick between flood and spot with a simple thumb slider switch.
My other mate has one on these H7 units but he’s still got 3 x AAA in his. Gets dark quite quicky. The figures of ‘up to 130 hours’ burn time are I suspect from full new batteries running at less than full power to just a glow. In practical terms, when used at full power with 3 x AAA, they started to fade slightly after about 75-90 minutes.
However, with 3 x AA, they still look the same after at least 3 hours at full power.
If anyone wants to build one, I’ll gladly help with the finer points, of course.