DIY Spotlight to Floodlight Headlamp

If you're interested in spotlight headlamps and floodlight headlamps, you might want to check out this article. If the lens of your spotlight headlamp is cracked, try cutting off the spotlight part and converting it into a floodlight. Additionally, spotlight headlamps can cause eye strain when used at close distances.

To do this, you'll need to remove the front spotlight reflector and create a cover using two pieces of acrylic.

The original lamp has two brightness settings: one for high beam direct light, and the other for low beam with a 1.5-ohm current-limiting resistor. The battery is charged directly, and it originally has a protection board.

You'll need to rework the circuit board by replacing the two settings with two QX7136 constant current drivers, and adding a 4056 charging control module.

Next, it's time to solder. If the current detection resistor isn't surface-mounted, you can use two 1-ohm resistors for the low beam (100mA). For the high beam, you can use three 1-ohm resistors in parallel. If you feel the 150mA current isn't bright enough or isn't generating much heat, you can replace the resistors with surface-mounted ones to adjust the current to 150mA or even 200mA for brighter light.

Finally, assemble the board and cover it with the cap.

The light effect is as shown below.

Done.