Low profile sexy DIY headlights

ESK8 Electronics
1

Here’s a quick guide on how to make some small headlights for your esk8 build that are quite bright and pretty nice looking. I used these headlights in a recent custom build (full build log is coming soon).

Stuff required:

  • 4x 3W LEDs (such as these)
  • Aluminum sheet
  • Thermally conductive adhesive
  • Epoxy
  • 3D Printer
  • Small heatsinks (such as these)
  • Clear acrylic sheet

The heatsinks might seem like a niche thing, but I guess I just had those laying around from an old project…not expensive though

Build steps:

  1. Solder together LEDs

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11512×2016 1.16 MB

  1. Cut out small pieces of aluminum sheet and mount heatsinks to back with thermal adhesive

2
23024×4032 3.25 MB

  1. Mount LEDs to heatsink assembly with thermal adhesive

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33024×4032 3.53 MB

  1. Insert LED assembly into 3D printed case (STL below) and solder on wires

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43024×4032 3.47 MB

  1. Cut out small acrylic covers and epoxy them on

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53024×4032 3.59 MB

  1. Profit:

beam profile:

6
64032×3024 3.66 MB

from the front:

7
74032×3024 2.09 MB

STL for the case: headlight_case.zip (27.3 KB)

1 Like
2

What kinda power is required to drive these?

Do they need a step-down/buck converter to bring the voltage down to a usable level?

3

Yes, a buck converter is necessary for most situations unless you happen to have enough LEDs in series so that their forward voltage combined is approximately the battery voltage. I’m using a LM2596 buck converter putting out 15V – my main pack is 6S, which fits within the 35V max input voltage for this chip. I have 4 LEDs in series along with a 10 ohm resistor, so they’re probably pulling 100mA at a forward voltage of 3.5V each. Plenty bright though!