OK gang. I sent out a bunch of you guys plans on how to build a hard hat light.

Lets see some pictures and stories of the results

I'm not sure what your design was but this is what I created prior to last duck season.

I just made a headlamp for hunting. I was hoping to get some comments/suggestions/criticism on my design.

Here is what I came up with.
I bought a 3' piece of aluminum strap at ACE - $4
4509 bulb at Napa - $13.50
I bought a stainless hose clamp - $2
bought two alligator clamps for the battery - $1.50/ea
20' green extension cord from ACE - $6
I already had a hardhat but they run about - $10
TOTAL - $28.50 ($38.50 if you don't have a hard hat)

I bent the strap to fit the contour of the helmet (2 pieces for top and bottom.) then riveted it to the helmet. I then riveted the hose clamp to the strap. I took a piece of 3/8 hose and cut it on the bottom side to wrap around the bulb to give the hose clamp something to hold to. then wired the bulb with the extension cord and D-O-N-E!






Of course I had to paint it camo..... because you have to paint everything camo.... :toothy10: I used it saturday morning and it worked flawlessly. It is a little heavy up front mostly due to the weight of the bulb but it was fine for the 30 to 45 minutes I wore it. If only I didn't have the motor problems that morning it would have been an excellent hunt.....

wow.jpg

My only issue with that is the bulb is exposed, and in my boats or the boats that I ride it, that would get broken.

We used funnels to protect the bulb ($3 from autozone). We also put in line switches so that you don't have to leave on the whole time...

Used last season-worked fine...

Here is a pic of another one I just built...

HardHatlight.jpg

VERY nice! Much cleaner design for sure. I was thinking of revising mine for the durability issue. It got banged around a little last season with no issue. A switch would be cool too. I'd like to try a halogen bulb because this thing gets a little heavy after a while.

FYI..

By the far the best route to go if in the Morgan City area is Aucoins Hardware.

Happened to be in there a couple of weeks ago and saw them.

Very clean hat and the price was great-think it was $59.. just remember thinking they were cleaner than ours and the price is barely over what I had in parts.

I would do that before building another one if I was in that area...

Also, if you build one, make sure you get the ratchet type. You will need to adjust the size based on hats, caps, etc.... and you want it tight or it will bounce of. You can dial those in faster and easier than the pin type.

Unfortunately, I had already built ours and don't live down there if I need another one...

good review! thanks

Now if I can find someone round HERE thats going down THERE!!!

Nice job, Jeep. simple & clean

The only problem I see is the same one I had with my first try at building one. I use about the sme style as caddobrook and if the bulb does not sit deep enough in the funnel, you get a lot of side-scatter of light down into the boat. I have found that if the bulb sits down in the funnel 1/2 to 3/4 of an inch, it projects the beam ont in front of the boat a lot better. Makes it a bunch easer to see

You guys need to try "Aircraft Spruce" on the internet for the bulbs. About $8.00 and sone change

A few years ago some directions got put together with a parts list.

http://www.drundel.com/hunt/hardhatlight/

Yea, thats the directions I used when I made mine