Cateye HL-500 bulb upgrade.

Hello all.

If possible I want to increase the brightness of my Cateye HL-500, yes
the most common of all bicycle lights.

How should I achieve this? New bulb? Higher voltage batteries (do these
exist? 1.5V Cs for example?)?

The light looks like this one:
http://www.cyclestore.co.uk/productD...productID=7968

The bulb is the GH182 from this list:
http://www.reflectalite.com/halogenpage.html

This site also suggests bulb alternatives but non are listed for this.
Does anyone have any experience in upgrading the bulb in this headlight?

The average output according to the table is 11 lumens and the bulb can
handle 2.5v, 0.5A and produces 1.25W power. The bulb base is: P13.5S.

This bulb from SJS Cycles:
http://www.sjscycles.co.uk/product-R...olt-0.8-Amp-2-
Watt-Push-Fit-Pre-Focus-Halogen-Bulb-GH155-4322.htm

Or TinyURL:
http://tinyurl.com/mfj45s

Is 0.8A and 2W and says is for the HL-500. Can I expect a decent
brightness increase or should I go slightly higher and devise some
rudimentary heatsink device from foil?

Additionally/Alternatively, what can I do to push a slightly higher
voltage through the existing bulb? Is it possible to buy standard size/
designations of cells with a slightly higher voltage? A quick google
suggests not but checking if there's some specialist alternative of which
I don't know.

Cheers

On Sun, 09 Aug 2009 16:24:04 +0000, Keiron wrote:

Hello all.

If possible I want to increase the brightness of my Cateye HL-500, yes
the most common of all bicycle lights.

How should I achieve this? New bulb? Higher voltage batteries (do these
exist? 1.5V Cs for example?)?

The light looks like this one:
http://www.cyclestore.co.uk/productD...productID=7968

The bulb is the GH182 from this list:
http://www.reflectalite.com/halogenpage.html

This site also suggests bulb alternatives but non are listed for this.
Does anyone have any experience in upgrading the bulb in this headlight?

The average output according to the table is 11 lumens and the bulb can
handle 2.5v, 0.5A and produces 1.25W power. The bulb base is: P13.5S.

This bulb from SJS Cycles:
http://www.sjscycles.co.uk/product-R...olt-0.8-Amp-2-
Watt-Push-Fit-Pre-Focus-Halogen-Bulb-GH155-4322.htm

Or TinyURL:
http://tinyurl.com/mfj45s

Is 0.8A and 2W and says is for the HL-500. Can I expect a decent
brightness increase or should I go slightly higher and devise some
rudimentary heatsink device from foil?

Additionally/Alternatively, what can I do to push a slightly higher
voltage through the existing bulb? Is it possible to buy standard size/
designations of cells with a slightly higher voltage? A quick google
suggests not but checking if there's some specialist alternative of
which I don't know.

Cheers

TYPO:
Where I say 1.5V Cs I mean rechargeables. Although are there non-
rechargeables at above 1.5V?

"Keiron" wrote in message
...
Hello all.

If possible I want to increase the brightness of my Cateye HL-500, yes
the most common of all bicycle lights.

How should I achieve this? New bulb? Higher voltage batteries (do these
exist? 1.5V Cs for example?)?

Boring answer : new lamp. Something LED based. Much better than faffing
around modding a crappy HL-500.

Re voltage - your rechargables are 1.2V rather than 1.5, and IIRC that lamp
is a 2 cell unit, so you're never going to do brilliantly with ot. Rejigging
it to take 5 rechargable cells and a 6V bulb would win you a lot. But see
above :-)

On Sun, 09 Aug 2009 17:37:58 +0100, Clive George wrote:

"Keiron" wrote in message
...
Hello all.

If possible I want to increase the brightness of my Cateye HL-500, yes
the most common of all bicycle lights.

How should I achieve this? New bulb? Higher voltage batteries (do these
exist? 1.5V Cs for example?)?

Hi Clive,

Boring answer : new lamp. Something LED based. Much better than faffing
around modding a crappy HL-500.

Yeah appreciate this and in fact already have other, superior
alternatives. Just want to 'faff' for.... fun I guess.

Re voltage - your rechargables are 1.2V rather than 1.5, and IIRC that
lamp is a 2 cell unit, so you're never going to do brilliantly with ot.
Rejigging it to take 5 rechargable cells and a 6V bulb would win you a
lot. But see above :-)

I wouldn't mind rigging it with an external battery pack but I don't want
to go crazy with the mods hence I'm not sure 6 V wouldn't melt the thing
without serious (and then even more senseless) upgrading than I'm already
suggesting.

I have however just spotted a 2.8 volt bulb running at 2.25 watt which I
venture might not run too hot but then how do I apply the extra 0.3V to
the bulb to take advantage of this?

Thanks

On 9 Aug, 17:32, Keiron wrote:
On Sun, 09 Aug 2009 16:24:04 +0000, Keiron wrote:
Hello all.

If possible I want to increase the brightness of my Cateye HL-500, yes
the most common of all bicycle lights.

How should I achieve this? New bulb? Higher voltage batteries (do these
exist? 1.5V Cs for example?)?

The light looks like this one:
http://www.cyclestore.co.uk/productD...productID=7968

The bulb is the GH182 from this list:
http://www.reflectalite.com/halogenpage.html

This site also suggests bulb alternatives but non are listed for this.
Does anyone have any experience in upgrading the bulb in this headlight?

The average output according to the table is 11 lumens and the bulb can
handle 2.5v, 0.5A and produces 1.25W power. The bulb base is: P13.5S.

This bulb from SJS Cycles:
http://www.sjscycles.co.uk/product-R...olt-0.8-Amp-2-
Watt-Push-Fit-Pre-Focus-Halogen-Bulb-GH155-4322.htm

Or TinyURL:
http://tinyurl.com/mfj45s

Is 0.8A and 2W and says is for the HL-500. Can I expect a decent
brightness increase or should I go slightly higher and devise some
rudimentary heatsink device from foil?

Additionally/Alternatively, what can I do to push a slightly higher
voltage through the existing bulb? Is it possible to buy standard size/
designations of cells with a slightly higher voltage? A quick google
suggests not but checking if there's some specialist alternative of
which I don't know.

Cheers

TYPO:
Where I say 1.5V Cs I mean rechargeables. Although are there non-
rechargeables at above 1.5V?

Dry cell batteries do have differing working voltages due to internal
resistance 1.5v is the nominal working voltage. filament bulb are
always over volted. I have used a 4 cell lead acid on a 4.8v
filament, it was brilliant. It didn't last long in a hand torch but
did give an incredible amount of light. About 8.5v. I am now using a
6v bulb with the 4cell gel lead acid battery which seems ok. I think
4.8v running 8v may work longer on a bicycle with some cooling air.
You need to get a higher wattage bulb anyway and then check each brand
of batteries you use for working voltage in mid life.

Back to dry cells. Surprisingly, the cheaper cells can perform better
in this respect (high working voltage) although may not give the
lifespan. It all depends how cheap you can buy whether it is worth
prusuing with filament systems. Or reclaim the cells. Get halogen
bulbs (krypton) and seriously overvolt them if you can.

If the lamp gives a good pattern I think it is worthwhile trying to
get more light. The worst that can happen is that you will melt the
reflector, but at least it will have worked well for a short while.
So go for an external battery if need be and dont pay too much
attention to bulb voltage versus battery voltage. If it lives, burns
white and does not blacken the bulb you have a success.

Maplin have halogen torch bulbs. Some electrical wholesalers (trade)
also stock low voltage bulbs.

On 9 Aug, 17:47, Keiron wrote:
On Sun, 09 Aug 2009 17:37:58 +0100, Clive George wrote:
"Keiron" wrote in message
...
Hello all.

If possible I want to increase the brightness of my Cateye HL-500, yes
the most common of all bicycle lights.

How should I achieve this? New bulb? Higher voltage batteries (do these
exist? 1.5V Cs for example?)?

Hi Clive,

Boring answer : new lamp. Something LED based. Much better than faffing
around modding a crappy HL-500.

Yeah appreciate this and in fact already have other, superior
alternatives. Just want to 'faff' for.... fun I guess.

Re voltage - your rechargables are 1.2V rather than 1.5, and IIRC that
lamp is a 2 cell unit, so you're never going to do brilliantly with ot.
Rejigging it to take 5 rechargable cells and a 6V bulb would win you a
lot. But see above :-)

I wouldn't mind rigging it with an external battery pack but I don't want
to go crazy with the mods hence I'm not sure 6 V wouldn't melt the thing
without serious (and then even more senseless) upgrading than I'm already
suggesting.

I have however just spotted a 2.8 volt bulb running at 2.25 watt which I
venture might not run too hot but then how do I apply the extra 0.3V to
the bulb to take advantage of this?

Thanks

Start with three ni-cads. You really want to be running 3w. With
overvolting you will probably get this with a white light. 3 ni-cads
will run about 3.6v two dry cells probably wont give enough
illumination. It is trial and error to get white light and good bulb
life. Always carry a safe running spare bulb (near to supply voltage)
for when the over volted bulb blows (not necessarily).

On Aug 9, 11:37*am, "Clive George" wrote:
"Keiron" wrote in message

...

Hello all.

If possible I want to increase the brightness of my Cateye HL-500, yes
the most common of all bicycle lights.

How should I achieve this? New bulb? Higher voltage batteries (do these
exist? 1.5V Cs for example?)?

Boring answer : new lamp. Something LED based. Much better than faffing
around modding a crappy HL-500.

No kidding. And cheap too. The Planet Bike range has a good
performance to cost ratio.

http://ecom1.planetbike.com/headlights.html

Or get a good bottle generator system and never fool with batteries
again.

On 9 Aug, 21:32, landotter wrote:
On Aug 9, 11:37*am, "Clive George" wrote:

"Keiron" wrote in message

...

Hello all.

If possible I want to increase the brightness of my Cateye HL-500, yes
the most common of all bicycle lights.

How should I achieve this? New bulb? Higher voltage batteries (do these
exist? 1.5V Cs for example?)?

Boring answer : new lamp. Something LED based. Much better than faffing
around modding a crappy HL-500.

No kidding. And cheap too. The Planet Bike range has a good
performance to cost ratio.

http://ecom1.planetbike.com/headlights.html

Or get a good bottle generator system and never fool with batteries
again.

Using a 'lantern battery' pj996 or something like that, with a flex
attatched to the bulb and terminated in two croc clips makes the most
reliable front lamp system. No switch, no unreliable battery
contact, the only connexions are solder from the bulb to the wire and
from the wire to the clips and the clips to the battery which is
sealed. Even the croc clips can be done away with and the wire
soldered to the battery terminal with a small butane torch. Something
else to fit in my bar bag. Probably better to clamp the last wire to
the spring battery terminal with a connexion block or crimp.

On Aug 9, 12:24*pm, Keiron wrote:
Hello all.

If possible I want to increase the brightness of my Cateye HL-500, yes
the most common of all bicycle lights.

How should I achieve this? New bulb? Higher voltage batteries (do these
exist? 1.5V Cs for example?)?

The light looks like this one:http://www.cyclestore.co.uk/productD...productID=7968

The bulb is the GH182 from this list:http://www.reflectalite.com/halogenpage.html

This site also suggests bulb alternatives but non are listed for this.
Does anyone have any experience in upgrading the bulb in this headlight?

The average output according to the table is 11 lumens and the bulb can
handle 2.5v, 0.5A and produces 1.25W power. The bulb base is: P13.5S.

This bulb from SJS Cycles:
http://www.sjscycles.co.uk/product-R...olt-0.8-Amp-2-
Watt-Push-Fit-Pre-Focus-Halogen-Bulb-GH155-4322.htm

Or TinyURL:http://tinyurl.com/mfj45s

Is 0.8A and 2W and says is for the HL-500. Can I expect a decent
brightness increase or should I go slightly higher and devise some
rudimentary heatsink device from foil?

Additionally/Alternatively, what can I do to push a slightly higher
voltage through the existing bulb? Is it possible to buy standard size/
designations of cells with a slightly higher voltage? A quick google
suggests not but checking if there's some specialist alternative of which
I don't know.

Cheers

My advice, based on direct experience:

Forget it. Buy another headlamp.

I tried _exactly_ what you're discussing many years ago. I fitted
some higher wattage halogen bulbs, because I did like Cateye's beam.
(Sorry, don't remember exactly what bulbs.) It worked quite well for
about 20 minutes, IIRC. Then the lights went out. The heat from the
bulbs flanges softened the reflectors until the bulbs lost contact
with their electrical connections. At that point, the reflectors were
not quite toast, but never the same.

If you wait a year or two, there may be much brighter LED replacements
for most of the filament bulbs listed at Reflectalite. (I'm only
guessing, but I see that happening for flashlight bulbs and night
light bulbs right now.) If that happens, you can resurrect your
headlights easily.

I just gave someone the $40 Planet Bike 1 Watt LED light as a gift.
It's the first small headlight I've tested that I consider pretty much
equal to my good generator setup. Except, of course, that it lacks
the "no battery, no theft, always ready on the bike" benefits of a
generator light, and its optics, like most such lights, could be way
better.

My advice, assuming you're not a generator guy:

Since LED technology is advancing as rapidly as computer chip
technology did in the 1980s, or digital cameras in the 2000s, you
should watch the progress until you spot your personal "good enough."
Then buy something, and don't worry that it will be outmoded in a year
or two. And realize that spending $40 saved you at least five hours
of work... or unproductive experimenting. And your time is worth
that, no?

The Planet Bike will probably be "good enough" for most people. It
will surely blow your Cateyes away!

- Frank Krygowski

On Aug 9, 12:37*pm, "Clive George" wrote:

Re voltage - your rechargables are 1.2V rather than 1.5, and IIRC that lamp
is a 2 cell unit, so you're never going to do brilliantly with ot. Rejigging
it to take 5 rechargable cells and a 6V bulb would win you a lot. But see
above :-)

About the 1.5 V vs. 1.2 V: It's not usually a problem. Here's why.

The voltage measurements quoted are measured at zero current flow. In
practice, when batteries are powering a light, they produce _less_
voltage at the bulb, because the batteries have internal resistance.
The more current flow, the less voltage they produce.

How much less? It depends not only on the current flow, but on the
type of battery. Serendipitously, rechargeables have much less
internal resistance than non-rechargeable batteries. So in practice,
two 1.2 V rechargeables produce almost exactly the same voltage at the
bulb as two 1.5 V NiCads. At least, that's what I found when I
measured them a few times.

Now, about over-volting bulbs: If you apply more than the rated
voltage to a bulb, you'll get brighter light out of it, and you'll get
more efficiency, but _much_ reduced life. Some filament bulbs (like
those once used for important indicator lamps) are designed to last a
long, long time under their rated voltage, but to do that, they accept
low brightness and low efficiency. Ovr-volting them a bit may not
matter.

Bike headlight bulbs tend to be designed at the other end of the
scale. They're already sort of over-volted compared to other bulbs,
since bikes aren't ridden all that much at night, and people want them
to be bright. Pushing them harder will probably give much shorter
life. Maybe still satisfactory for you, depending how much you ride
at night - but carry spares!

- Frank Krygowski