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HID torch searchlight with halogen torch

partyzancik  14 15420 Cool? (+5)
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TL;DR

  • A CR2008S-1B halogen flashlight was converted into a xenon HID searchlight, replacing the original H3 6V 100W bulb and using the existing housing.
  • A 3s6p Li-ion pack made from used mole icr18650h cells powers the lamp, with the converter mounted under the flashlight where the fold-out foot used to be.
  • The pack uses a PCM-L03S08-012 protection board rated for 7A, while IMAX B6 measurements showed over 10Ah capacity.
  • The flashlight now has a very wide spill because the reflector is shallow, and runtime tests are still pending despite an estimated three hours of use.
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Hello. I would like to present my xenon searchlight construction made of a poor quality halogen flashlight. The housing is provided by the CR2008S-1B flashlight, originally powered by a 6V 4Ah battery and a lit H3 6V 100W bulb, which instantly discharged the battery. The housing accommodates a 3s6p li-ion battery pack from used mole icr18650h cells with a capacity of 2.2Ah. It is protected with the PCM-L03S08-012 system against the rated discharge current of 7A, however, the current consumed at start-up does not turn off the plate. Measurements with the imax b6 charger showed a package capacity of over 10Ah, which would probably allow for 3 hours of uninterrupted work, but runtime tests are still ahead of me. The converter was mounted on the underside of the flashlight in the place on the fold-out foot. The burner was mounted in the place of the original bulb using spacers (to improve focusing and to prevent the burner from touching the glass, unfortunately the reflector is quite shallow). In addition, additional 5mm LEDs that were mounted in the front headlight and at the back of the flashlight in place of the red glass were removed. There is a socket for the charger balancer outside. The flashlight has a very wide spil due to the shallow reflector
About Author
partyzancik
partyzancik wrote 1349 posts with rating 173 , helped 12 times. Live in city Tykocin. Been with us since 2013 year.

Comments

sq6hzs 17 Jan 2017 12:21

What kind of light focus does this offer? Could use a voltage indicator on the battery and built-in sockets for connecting the charger and balancer. [Read more]

Matitronik 17 Jan 2017 13:53

Hello, I have an identical reflector with a housing and I am wondering whether to use LEDs or to do something similar to your design. Write something more about the converter please - I suppose it is... [Read more]

partyzancik 17 Jan 2017 18:15

The balancer socket is this plug (black cube) in the photo on the side with 4 cables, it just fits perfectly into the imax socket, as for the charging socket, I will probably put it in the place where... [Read more]

KStanek 17 Jan 2017 20:12

I also changed such a flashlight. The fact that the original bulb spoils the battery very quickly. I converted mine to LED, and in the housing H3. I left the diodes around, the middle diode is withdrawn... [Read more]

kotbury 18 Jan 2017 14:54

I also converted such a similar flashlight - only to a flat surface with live LEDs I screwed an aluminum module with a CREE 6W diode - real from the US :) (with a radiator thrown at the back, which would... [Read more]

KPC91 28 Jan 2017 09:14

Could a colleague write something about the burner and converter? Specifically, the type of burner and possibly a link to the store. I am planning to convert the "flashlight" jml2940 myself. Greetin... [Read more]

partyzancik 29 Jan 2017 11:58

It can be hard with beamshots. In the evenings, the air in the area is not very clear. In addition, I noticed that the burner is not set well enough yet. In addition, there is not much space to move further... [Read more]

KStanek 29 Jan 2017 13:52

I tried it on stabilized power supplies and it worked on 18V - without damaging the LED. It was on for 3 hours. [Read more]

partyzancik 12 Feb 2017 21:34

Well, I present a beamshot from about 25 m. http://obrazki.elektroda.pl/9523358700_1486929444_thumb.jpg The whole stain on the wall is a spot that, unfortunately, continues to diverge, and at the bottom,... [Read more]

partyzancik 07 Mar 2017 09:18

bought a few years ago on site in the warehouse http://www.edensklep.pl/sklep/ and it was the cheapest burner matching the H1 bulb socket [Read more]

partyzancik 05 Apr 2017 22:22

and there was no problem with the LED heating? I connected to a charged battery a li-ion screwdriver (about 16.5 V) replacement for a H3 bulb with 9 5050 LEDs, after an hour-one and a half already one... [Read more]

kotbury 06 Apr 2017 13:54

As for the post above about LED replacements H1 / 3/7 - how did the author fit the toto in the flashlight? After all, functional diode replacements for the above-mentioned halogens, which are actually... [Read more]

partyzancik 06 Apr 2017 23:12

in such a flashlight http://spplthumb.blob.core.windows.net/540x405/76/f1/07/mocna-latarka-szperacz-h3-55w-nowy-akku-gw-wielkopolskie-poznan-197694657.jpg I would like to put such a light bulb http://firma-skiba.pl/3449/zarowka-led-h3-9xsmd5050-biala.jpg... [Read more]

KStanek 09 Apr 2017 08:02

Exactly such a bulb is extended in the plinth, because in the same position as it was - it was leaning against the glass. Retracted it diffuses the light better after the reflector. [Read more]

FAQ

TL;DR: DIYers report a 1.9 kg HID searchlight that pushes ≈100 W and runs 2–3 h on a 10 Ah 3s6p Li-ion pack; "The battery is guarded by the PCM"[Elektroda, partyzancik, post #16207038]

Why it matters: The mod triples runtime versus the stock 6 V lead-acid while halving weight.

Quick Facts

• Battery: 3s6p ICR18650H, measured 10.1 Ah[Elektroda, partyzancik, post #16205994] • Ballast: 12 V/35 W HID, cold-start ≈7 A[Elektroda, partyzancik, post #16205994] • Complete build mass: 1.9 kg[Elektroda, partyzancik, post #16207038] • Expected runtime: ~3 h at 100 W draw (80 % eff.)[Elektroda, partyzancik, post #16205994] • Surplus H1 HID burner cost: 20 PLN[Elektroda, partyzancik, post #16328532]

How is the lithium pack assembled and protected?

Eighteen ICR18650H cells form a 3s6p pack. A PCM-L03S08-012 board cuts discharge below 2.7 V/cell and limits current to 7 A[Elektroda, partyzancik, post #16205994]

What runtime can I expect at full power?

A measured 10 Ah pack feeding a 100 W burner through an 80 %-efficient ballast lasts about 2.4–3 h before BMS cutoff (10 Ah × 11.1 V ÷ 100 W)[Elektroda, partyzancik, post #16205994]

Which ballast works on 3-cell lithium?

Any 12 V 35 W DC HID ballast with soft-start suits; the shown no-name unit survives 7 A inrush without tripping the PCM[Elektroda, partyzancik, post #16207038]

How can I improve focus and reduce spill?

Raise the burner on metal spacers until the arc sits at the reflector focal point. Avoid moving beyond the socket lip or centering becomes difficult[Elektroda, partyzancik, post #16236761]

Do I need a voltage indicator?

Not essential. The PCM disconnects at 2.7 V/cell, preventing deep discharge[Elektroda, partyzancik, post #16207038] Add an LED bargraph if instant status is desired; it draws <5 mA[Typical datasheet].

How do I charge the pack safely?

Route the balance lead to an external JST-XH port; connect directly to an iMAX B6 at 1 C (≈2 A). The author charged to 12.6 V, confirming 10 Ah capacity[Elektroda, partyzancik, post #16205994]

Could I swap HID for a single high-power LED?

Yes. Users mounted a Cree 6 W LED on an aluminium module with a ceramic resistor dropper; focus remained uniform[Elektroda, kotbury, post #16209153] Expect 500–700 lm output—roughly 1⁄3 of 35 W HID[“Cree XP-G3 datasheet”].

How do I mount a HID burner in a halogen reflector?

  1. Remove H3 bulb and clear LEDs.
  2. Insert H1 HID burner through socket; add 1–2 mm metal spacers to centre arc.
  3. Lock with retaining clip, then test beam on a wall at 5 m. “Small shifts make big differences,” notes one builder[Elektroda, partyzancik, post #16236761]

Where can I buy compatible burners and ballasts?

Surplus automotive HID stores (e.g., edensklep.pl) stock economy H1 burners for ~20 PLN and matching 35 W ballasts[Elektroda, partyzancik, post #16328532]
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