Another homemade bike light - Cycling Mob: Road Cycling, Mountain Biking and More

10-09-2003, 11:40 PM

I've used my dual beam Jet Lites for 3 seasons and it's seems the
batteries are kaput. I charged them up the other day and the battery was
warm as they usually are after charging but no lights. I only use them
during Daylight Saving Time so they've been sitting around for several
months.
Anyway, a new battery pack from them will cost me $150 which seems
ridiculous. I took the pack apart and it seems pretty simple to do.
It's 11 NiMH batteries wired in series. It's 13.2V total so 1.2V per
battery at 350mAh each (3800mAh total). I'd like to just replace the
batteries but most premade packs are underpowered compared to these.
Would I need to get a whole new charger for less volts? If I switched to
lead acid or NiCd, would I need a new charger, too?

Thanks, Paul

10-10-2003, 01:17 AM

On Fri, 10 Oct 2003 06:40:47 +0000 (UTC), [Only registered and activated users can see links. ] wrote:

> I've used my dual beam Jet Lites for 3 seasons and it's seems the
>batteries are kaput. I charged them up the other day and the battery was
>warm as they usually are after charging but no lights. I only use them
>during Daylight Saving Time so they've been sitting around for several
>months.
> Anyway, a new battery pack from them will cost me $150 which seems
>ridiculous. I took the pack apart and it seems pretty simple to do.
>It's 11 NiMH batteries wired in series. It's 13.2V total so 1.2V per
>battery at 350mAh each (3800mAh total). I'd like to just replace the
>batteries but most premade packs are underpowered compared to these.
>Would I need to get a whole new charger for less volts? If I switched to
>lead acid or NiCd, would I need a new charger, too?
>
> Thanks, Paul
nope, 350 mAh total. if your interested, ill explain it. ill pull out
my jkarcar catalogue and check the price of NiMH batteries. 350mAh
seems ridiculously small though. My battery is 7000mAh. If you buy AA
NiMH batteries, you can get 11 for 36 dollars 30 cents, with solder
tabs, jaycar cat sb-1732. THese are 1200mAh, and if you have a smart
charger it may well mean you need to get a new one. Ifyour charger is
just a plugpack thingey, youll just need to leave it connected longer.
if its a 120mA charger, youll need to leave it connected for 15
hours, if its a 350 mA charger youll need to connect it for 5 hours.
If its a 1200 mA charger, you need to leave it connected for 1.5
houirs. THats the lighter solution. another option is to go with lead
acid battery, they really will be tiny if you only want a bit of
capacity. A 1300 mAh would suit your purposes very well, and is only
97mmdx43mmx57mm. because its so small, it may well be lighter than the
nimh batteries, because it doesnt have so much packaging. If its
heavier it wont be much so. It'll be more elgant becasue you dont have
to solder lots of batteries together, and you can attach it direct to
a bar with cable ties. Its also VERY rugged, so good for offroading.
Its $24.95 , but you need a special charger for 33 dollars.

I wouldnt really reccomend using a light which was designed to work
with 350mAh batteries off road though. If you ever cycle near the st
ives area maybe i can show you my battery and light sometime

55
watts >

10-10-2003, 03:28 AM

On Fri, 10 Oct 2003 06:40:47 +0000 (UTC), [Only registered and activated users can see links. ] wrote:

> I've used my dual beam Jet Lites for 3 seasons and it's seems the
>batteries are kaput. I charged them up the other day and the battery was
>warm as they usually are after charging but no lights. I only use them
>during Daylight Saving Time so they've been sitting around for several
>months.
> Anyway, a new battery pack from them will cost me $150 which seems
>ridiculous. I took the pack apart and it seems pretty simple to do.
>It's 11 NiMH batteries wired in series. It's 13.2V total so 1.2V per
>battery at 350mAh each (3800mAh total). I'd like to just replace the
>batteries but most premade packs are underpowered compared to these.
>Would I need to get a whole new charger for less volts? If I switched to
>lead acid or NiCd, would I need a new charger, too?
>
> Thanks, Paul
[Only registered and activated users can see links. ]

FYI - 11 350mah battereis wired in series has a capacity of 350mah.
Its likely that they are the HR-4/3FAUX 4500mah batteries, many of the
12v bike systems use this battery (niterider for sure).

10-10-2003, 03:44 AM

GregR wrote:
: On Fri, 10 Oct 2003 06:40:47 +0000 (UTC), [Only registered and activated users can see links. ] wrote:
:
:> I've used my dual beam Jet Lites for 3 seasons and it's seems the
:>batteries are kaput. I charged them up the other day and the battery was
:>warm as they usually are after charging but no lights. I only use them
:>during Daylight Saving Time so they've been sitting around for several
:>months.
:> Anyway, a new battery pack from them will cost me $150 which seems
:>ridiculous. I took the pack apart and it seems pretty simple to do.
:>It's 11 NiMH batteries wired in series. It's 13.2V total so 1.2V per
:>battery at 350mAh each (3800mAh total). I'd like to just replace the
:>batteries but most premade packs are underpowered compared to these.
:>Would I need to get a whole new charger for less volts? If I switched to
:>lead acid or NiCd, would I need a new charger, too?
:>
:> Thanks, Paul
: [Only registered and activated users can see links. ]
:
: FYI - 11 350mah battereis wired in series has a capacity of 350mah.
: Its likely that they are the HR-4/3FAUX 4500mah batteries, many of the
: 12v bike systems use this battery (niterider for sure).

Well, that does explain a lot. Thanks. The system is 3800mah. It's been
too long since high school physics. I will try to look for those
batteries. Additionally, I do believe my charger is "smart" to some
degree. From the manual I am able to leave it plugged it and it will do a
"trickle" charge once the battery is full. If I go with the higher
capacity battery, does that mean the charger will take longer to charge or
is it just incompatible after 3800mah?

Thanks again

10-10-2003, 04:58 AM

On Fri, 10 Oct 2003 10:44:56 +0000 (UTC), [Only registered and activated users can see links. ] wrote:

>GregR wrote:
>: On Fri, 10 Oct 2003 06:40:47 +0000 (UTC), [Only registered and activated users can see links. ] wrote:
>:
>:> I've used my dual beam Jet Lites for 3 seasons and it's seems the
>:>batteries are kaput. I charged them up the other day and the battery was
>:>warm as they usually are after charging but no lights. I only use them
>:>during Daylight Saving Time so they've been sitting around for several
>:>months.
>:> Anyway, a new battery pack from them will cost me $150 which seems
>:>ridiculous. I took the pack apart and it seems pretty simple to do.
>:>It's 11 NiMH batteries wired in series. It's 13.2V total so 1.2V per
>:>battery at 350mAh each (3800mAh total). I'd like to just replace the
>:>batteries but most premade packs are underpowered compared to these.
>:>Would I need to get a whole new charger for less volts? If I switched to
>:>lead acid or NiCd, would I need a new charger, too?
>:>
>:> Thanks, Paul
>: [Only registered and activated users can see links. ]
>:
>: FYI - 11 350mah battereis wired in series has a capacity of 350mah.
>: Its likely that they are the HR-4/3FAUX 4500mah batteries, many of the
>: 12v bike systems use this battery (niterider for sure).
>
>Well, that does explain a lot. Thanks. The system is 3800mah. It's been
>too long since high school physics. I will try to look for those
>batteries.

AAAAAAAAAAAAAAAAHHHHHHHHH, dont bother. YOu'll get them for 7-0
dollars each. Still way expensive. Go SLA.
>Additionally, I do believe my charger is "smart" to some
>degree. From the manual I am able to leave it plugged it and it will do a
>"trickle" charge once the battery is full. If I go with the higher
>capacity battery, does that mean the charger will take longer to charge or
>is it just incompatible after 3800mah?
could be either. could be that it wont charge them completely. depends
on the design.
>
> Thanks again

10-10-2003, 05:29 AM

On Fri, 10 Oct 2003 06:40:47 +0000 (UTC), [Only registered and activated users can see links. ] wrote:

> I've used my dual beam Jet Lites for 3 seasons and it's seems the
>batteries are kaput. I charged them up the other day and the battery was
>warm as they usually are after charging but no lights. I only use them
>during Daylight Saving Time so they've been sitting around for several
>months.
> Anyway, a new battery pack from them will cost me $150 which seems
>ridiculous. I took the pack apart and it seems pretty simple to do.
>It's 11 NiMH batteries wired in series. It's 13.2V total so 1.2V per
>battery at 350mAh each (3800mAh total). I'd like to just replace the
>batteries but most premade packs are underpowered compared to these.
>Would I need to get a whole new charger for less volts? If I switched to
>lead acid or NiCd, would I need a new charger, too?
>
> Thanks, Paul

Why not have your battery rebuilt at much less than the cost of a new
one? Try one of these outfits:

The NiCad Lady (Grace) [Only registered and activated users can see links. ] or (909) 653-8868.
She also sells NiMh. You can get individual cells or she can assemble
custom configurations at a reasonable price.

or get a quote from:

PRIMECELL DIVISION
CUNARD ASSOCIATES INC.

[Only registered and activated users can see links. ]

10-10-2003, 05:34 AM

On Fri, 10 Oct 2003 12:29:54 GMT, Joe <[Only registered and activated users can see links. ]>
wrote:
Thanks, Paul
>
>Why not have your battery rebuilt at much less than the cost of a new
>one? Try one of these outfits:
>
>The NiCad Lady (Grace) [Only registered and activated users can see links. ] or (909) 653-8868.
>She also sells NiMh. You can get individual cells or she can assemble
>custom configurations at a reasonable price.
>
>or get a quote from:
>
>PRIMECELL DIVISION
>CUNARD ASSOCIATES INC.
>
>[Only registered and activated users can see links. ]

One other outfit with nationwide outlets you might want to try is:
Batteries Plus

[Only registered and activated users can see links. ]

10-10-2003, 10:26 AM

Arpit <[Only registered and activated users can see links. ].au> wrote:
: AAAAAAAAAAAAAAAAHHHHHHHHH, dont bother. YOu'll get them for 7-0
: dollars each. Still way expensive. Go SLA.

Thanks to all the replies! I found the same batteries at batterystation.com
for $2.50 each ($27.50 for 11). Another place has 10 C cells for $23 giving
me 12V at 4500mah--700 more than what I have now. The lights are 12V anyway;
JetLites just stick a little more juice in them for brightness. I don't ride
trails--just commuting. I wouldn't mind the extra running time. I'll let
you know how it goes.

10-11-2003, 04:33 AM

<[Only registered and activated users can see links. ]> wrote in message
news:bm5k9f$d9sh$[Only registered and activated users can see links. ]...
> I've used my dual beam Jet Lites for 3 seasons and it's seems the
> batteries are kaput. I charged them up the other day and the battery was
> warm as they usually are after charging but no lights. I only use them
> during Daylight Saving Time so they've been sitting around for several
> months.
> Anyway, a new battery pack from them will cost me $150 which seems
> ridiculous. I took the pack apart and it seems pretty simple to do.
> It's 11 NiMH batteries wired in series. It's 13.2V total so 1.2V per
> battery at 350mAh each (3800mAh total). I'd like to just replace the
> batteries but most premade packs are underpowered compared to these.
> Would I need to get a whole new charger for less volts? If I switched to
> lead acid or NiCd, would I need a new charger, too?

Check out: [Only registered and activated users can see links. ]

4500 mAH NiMH C cells are $4.50 each. Not sure how much they
charge for the welding. This would yield a 59WH pack. Can't
imagine they'd charge for than $40 or so for labor, but who
knows?

You could buy two 6 C cell battey holders and not weld the
batteries together (use one dummy cell), but the shape would
not be what you need, and it would be less reliable than
welding.

[Only registered and activated users can see links. ]

Solder the lugs very carefully to not melt the plastic, and use
heavy enough gauge wire for your lights (the tiny holes in the
solder tabs don't accept large enough gauge wire, they need
to be carefully enlarged).

Do not try to use AA cells, they cannot handle that much
current (don't go over a 1A discharge rate). You could
parallel AA NiMH packs to solve the discharge rate issue,
but you have to charge the packs serially, which is a
hassle. But AA cells are amazingly inexpensive, you can
get a pack of 10 2000mAH cells for less than $9.

Lead Acid would work if you don't mind the extra weight.
Remember that while a 60WH SLA is only about $11,
you'll actually need the 84WH SLA to about equal
the 50 WH NiMH capacity of your old pack. SLA battery
AH ratings are for a 20 hour discharge rate, at high discharge
rates the capacity is drastically reduced. You'll need a a
new charger, but SLA chargers are cheap. Check out
[Only registered and activated users can see links. ] for SLA batteries and chargers.

See my web site for more details on batteries and
chargers: [Only registered and activated users can see links. ].

Steve
[Only registered and activated users can see links. ]

10-11-2003, 07:31 AM

get the 4/3 aa batteries with solder tags

On Sat, 11 Oct 2003 11:33:22 GMT, "Steven M. Scharf"
<[Only registered and activated users can see links. ]> wrote:

><[Only registered and activated users can see links. ]> wrote in message
>news:bm5k9f$d9sh$[Only registered and activated users can see links. ]...
>> I've used my dual beam Jet Lites for 3 seasons and it's seems the
>> batteries are kaput. I charged them up the other day and the battery was
>> warm as they usually are after charging but no lights. I only use them
>> during Daylight Saving Time so they've been sitting around for several
>> months.
>> Anyway, a new battery pack from them will cost me $150 which seems
>> ridiculous. I took the pack apart and it seems pretty simple to do.
>> It's 11 NiMH batteries wired in series. It's 13.2V total so 1.2V per
>> battery at 350mAh each (3800mAh total). I'd like to just replace the
>> batteries but most premade packs are underpowered compared to these.
>> Would I need to get a whole new charger for less volts? If I switched to
>> lead acid or NiCd, would I need a new charger, too?
>
>Check out: [Only registered and activated users can see links. ]
>
>4500 mAH NiMH C cells are $4.50 each. Not sure how much they
>charge for the welding. This would yield a 59WH pack. Can't
>imagine they'd charge for than $40 or so for labor, but who
>knows?
>
>You could buy two 6 C cell battey holders and not weld the
>batteries together (use one dummy cell), but the shape would
>not be what you need, and it would be less reliable than
>welding.
>
>[Only registered and activated users can see links. ]
>
>Solder the lugs very carefully to not melt the plastic, and use
>heavy enough gauge wire for your lights (the tiny holes in the
>solder tabs don't accept large enough gauge wire, they need
>to be carefully enlarged).
>
>Do not try to use AA cells, they cannot handle that much
>current (don't go over a 1A discharge rate). You could
>parallel AA NiMH packs to solve the discharge rate issue,
>but you have to charge the packs serially, which is a
>hassle. But AA cells are amazingly inexpensive, you can
>get a pack of 10 2000mAH cells for less than $9.
>
>Lead Acid would work if you don't mind the extra weight.
>Remember that while a 60WH SLA is only about $11,
>you'll actually need the 84WH SLA to about equal
>the 50 WH NiMH capacity of your old pack. SLA battery
>AH ratings are for a 20 hour discharge rate, at high discharge
>rates the capacity is drastically reduced. You'll need a a
>new charger, but SLA chargers are cheap. Check out
>[Only registered and activated users can see links. ] for SLA batteries and chargers.
>
>See my web site for more details on batteries and
>chargers: [Only registered and activated users can see links. ].
>
>Steve
>[Only registered and activated users can see links. ]
>