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My new (old) headlight project

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Brutuskend

I live for the CABE
So I picked up a old 50's ? delta power king flashlight because the light itself looked very much like lights I have seen on older bikes. The lens was cheap plastic and it had been partially melted, also it didn't fit in the bezil very well so I went on a search for a nice glass lens 4 1/4 inch across. I didn't really find one until I came across a tractor light on Amazon. It was listed as being 4 1/2 across so I figured I would have to cut it down with a grinder after I disassembled the sealed beam light. Well the tractor light came today and after I took it apart, the lens turned out to fit PERFECTLY. I scraped out the glue holding the light together and here are the results.
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Just about done. I decided not to over build the battery tube and leave off the switch because the headlight already had a switch in it I opted to keep things simple. A lot of the paint was coming off of the headlight so I shot it and the bracket with silver hammer rite paint. I got conduit from a old pay phone and used that to protect the wiring. All I need now are the brackets. I ordered some kennel brackets from ebay which came today and they not only sent one's that looked totally wrong but 3 were one size and one was different, so those go back, or in the trash. Drum roll.....
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The battery tube is 1 3/8 aluminum tube and I was originaly going to use 3 "D" cell batteries but in the end I used a piece of pvc just the right size for "C" cell batteries (5) giving me 7.2 volts. I filed and sanded the pvc until it fit snugly into the tube, then honed the inside until the "c" cells fit nicely into the pvc tube. I made the cap from copper end caps and used 3 hammer rivets I bought for head badges. I made the connector for the top of the batteries out of various odds and ends I had kicking around. Once I get the clamps the finishing touch will be a delta decal I bought on ebay.
 
Really nice re-purposing. I tihnk I saw a reference here where someone had modified an old flash-lite body as a battery tube to give it a vintage look. THanks for posting this, it's inspiring!
Gary
 
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