Harbor Freight Hex Shaped Work Light 18650 Mod
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Harbor Freight magnetic base swivel work light. Added piggyback with 18650 battery and micro-USB charge port.
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Tired of buying AAA batteries and picking up light to see it not very bright when I needed it. To intricate for me to recreate black back housing so I went with the piggyback approach. The only modification to the original is one small hole in the black case and soldering to two battery contacts.
Parts and Supplies:
- 18650 lithium battery. I got mine from an old 20V drill battery that still had a good cell
- 5mm x 8mm long screw
- 5mm ID flat washer
- 20 to 22 gauge hookup wire, dissimilar colors help keep track
- hot glue, to tack charging board down
- drill bit, around 3/16" into black base for wires to pass through
- soldering iron and solder
- 1A micro USB charger, about everyone has one of these now
- Charging board, HiLetgo 5V 1A 18650 Lithium Battery Charging Board TP4056, bought 10 pc at Amazon for $7.79. (Dec 2022) Amazon.com: HiLetgo 10pcs 5V 1A 18650 Lithium Battery Charging Board TP4056 Lithium Battery Charging Board Micro USB Charge Module With Protect : Electronics
Separate light and remove batteries from light housing. Remove 5mm nut to separate swivel from base. Drill hole somewhere near center ring (see picture) Set aside for later.
Board is marked Bat + and - for battery hookup and Out + and - for light hookup. Keep the Out wires fairly long so it will be easier to solder to light. They can be folded up into the AAA battery cavity. Solder outside the case to keep from melting the plastic. Place battery and board assembly in case and tack board down with hot glue. Battery can be glued also if you wish.
Place case assembly on swivel hex and use printed hex nut to snug down. You can use 16mm or 5/8" long socket, hand tightened is sufficient. Fish light wire through hole in base. Test base alignment onto printed hex in case. Tighten or loosen nut until base hex and case hex align. Put on washer and 5mm screw and tighten base to case. Solder + wire to + pad in light case. (Single pad that battery positive tip would set on.) Solder - wire to - pad in light case. (Single pad with spring that battery negative end would set on.) Stuff excess wires into AAA battery compartment as you put light back on base. Can be tested or charged if needed. There will be some movement between base and case, it can be superglued or hot glued if that is a problem. Note: The battery charge port hole is offset for a reason. The charge board has two small LEDs on the offset side. Look into that side while charging and it will be red, when charged it will be blue.
Printed on Creality Ender 3, PLA filament, 0.2 layer, 30% infill, no supports
Hex Nut use 100% infill