Rayovac Luxeon Star Headlamp Mod:
Here is a photo of the partially completed, showing the Luxeon Star mounted on a heat sink. The battery pack that came with the headlamp is in view, and the second black project box contains a LM2595 step down regulator, and a on/off switch. Further modification includes a dimmer switch, for variable brightness setting.
A close up of the Luxeon Star inside the headlamp.
This is a fun light, and very functional. The stock headlamp was not 100% waterproof, as the way the power cord connect to the head would be a possible source of water leakage. I can seal the head to make it completely waterproof.

The swich/regulator box is too big. I need to make this smaller. I think the power pack should be moved to a belt battery pack, with the regulator switch with it or in it.

I will put the reflector in, but it will have to be cut way down, because there is not much room left. The heat sink takes up a lot of room. Behind the plate is a large aluminim block for additional heat sinking.

My oldest son named this the 'Cyborg', as wearing it makes a person look, well, like he belongs on Star Trek.
Home Page:
Flashlight modifications: