Ryobi 40 Volt Battery LED Spotlight
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An automotive small spotlight adapted to use a Ryobi 40 Volt battery.
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I started with a nice slide connector from OTandAT on Thingiverse. I built around it for the base. I made center section to house electrical and added a top cap to mount light.
Parts:
- 16 LED spotlight or your choice. Amazon 4 for $13, Temu 2 for $5.71 or 4 for $10.40.
- (5) 4mm countersunk screws
- (5) 4mm nuts
- (7) 3mm screws
- Rocker Switch for 10 x 16mm hole (Amazon)
- (2) 6mm / ¼" female terminals. Original listing said bought from AliExpress, I got mine from EBay, TE Connectivity 926965-1 Automotive Connector
- LM2596 Voltage Regulator DC to DC Converter (Amazon)
- Miscellaneous wire and hot glue
Bottom Assembly: The light pulls about 350ma, use wire for at least one amp, crimp into terminals and solder for secure connection. Put terminals in to base and slide onto battery to test for good alignment. Put wires through holes for wiring into middle section. Make sure terminals are pushed as far back as they can and seated down. Hot glue them in place. Screw the bottom and middle sections together. Check terminal lid for fit and trim nibs on one side to make sure lid fits flush. Put more hot glue over wires and terminal ends to fill cavity enough to contact the lid when assembling. If lid sets to high, it could interfere when the battery slides on.
Middle Assembly: Insert switch in top cover. The light can be put on now or later. If the switch has little nibs on the sides, they may need to be trimmed off to allow switch to be seated flush. Solder the + positive terminal wire to one side of the switch. Solder the - negative wire to the DC board IN -. Solder wire from the other switch to the DC board IN+.
Test and Regulate Power: Slide in battery and measure the DC board OUT - and +. Test switch to check power off and on. While on use small screwdriver on the blue potentiometer on the board to set it below 24 volts. I set mine to 20 volts. The spotlight works between 12 and 24 volts. When done, switch off and remove battery.
Top Assembly: If light has not been installed yet use hardware that came with it. I also used additional lock and flat washers with light (just my preference). Insert sheathed wires through top hole and trim most of the sheath back. Cut off excess wires. Solder red wire to OUT + and Black to OUT-. Flush cut any solder parts from bottom of board and set board in space provided. Hot glue board to middle section. Set top on middle and make sure it clips down all around before adding the 3mm screws. Slide on battery and test light. With a 350ma current draw it should be able to run for hours. I have not tested it for any length of time, but the board will produce some heat.