How to make a homemade LED flashlight

We present a manual for making a homemade LED flashlight, with which we can replace the traditional lamp of a flashlight with low-consumption LEDs, a good idea to have a homemade hand lamp. Remember that The great advantage of using this type of LED lamp is its low consumption and longer life compared to traditional lamps and even with low consumption..

How to make a homemade flashlight.

To achieve this, the following steps must be followed:

First of all, we have to keep in mind that depending on the design of the flashlight we are using, the final coupling may vary and we first need to know how the flashlight is composed in order to get started. to get your hands on it. So, let’s get to work and disassemble all the parts of the flashlight as we can see in the following pictures:

led lamp house 1

As we can see, there is nothing fancy. In this case, this flashlight uses a small holder for the bulb which in turn touches some copper plates in contact with the batteries via a switch on the top. You can also see that there is a small notch that we need to remove in order to remove the reflector, which is plastic. This will come in handy later when we anchor the final assembly in this site.

led lamp house 2

We first made some tests on a mounting model of some LED diodes and supplied them with 3 volts. All the diodes are connected in parallel and apparently everything is correct and we appreciate a strong white light.

led lamp house 3

We made a small printed circuit to house 52 diodes, which we explained in our previous tutorial on how to make a pcb which you can visit as a reference. So that when soldering everything is perfect, I usually use paste FLUX. While mounting and soldering all the diodes is not at all complicated, it does take some time, so be patient.

led lamp house 4

Once all the LEDs are soldered, we have a nice round plate ready to use. We also soldered a pair of cables with their respective colors (red and black) to take current from the batteries. We also see that the plate fits perfectly to the front of the lantern, as can be seen in this image:

led lamp house 5

Well, now comes the “a little more difficult” which consists in attaching the assembly to close the flashlight (which is threaded and waterproof) and also to take the current of the batteries. The first thing to do is to cut a piece of the reflector because the plate with the LED diodes is thicker and takes up a lot of space without being able to close the flashlight. We mark a little with the eye with a marker then we take our dremel (or similar) to make a cut as clean as possible:

led house lamp 6

We now have the assembly well positioned and this allows to close it without problem. What are we missing? then take current from the batteries.

led house lamp 7

We decided to tear off the original bulb and use its contacts to solder the power wires to the board. The glass part is carefully removed and the terminals cleaned.

led house lamp 8

Take advantage of the hole in the reflector to pass the cables to the bulb holder and solder with a little tin.

led house lamp 9

Once all the steps are done, here is the final result, which we can screw onto the body of the flashlight and start enjoying our own homemade flashlight with LED diodes!

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