NightSun Sunsport Light Modifications
(Archived from 2002)
I just bought a NightSun SunSport
helmet light - here's what I did to make it compatible with all of my existing
SunSport light, battery, and 240V charger. Since I have enough 110V
"homebrew" smart chargers, I got the 240V charger for travelling.
Note that the connectors are different and are not the standard Molex connectors
used in NightSun's older models.
I cut the end of the charger off and put standard Molex connectors on both
ends. This gives me a "converter piece" of wire so I can use my
other chargers to charge the battery. It also lets me use the 240V charger
for charging all of my other NightSun batteries.
I could have accomplished the same thing by replacing the black connectors
on the light and battery with Molex connectors, but there were two
problems with that. First, the on/off switch is an integral part of the
connector, so I would have had to add a switch, or unplug the battery to turn it
off. Second, the wire from the light is very thin, which would have made
it difficult to add connectors to it.
are pictures of the emergency battery backup for the light. I'll keep
these at work in case my batteries are running too low for my commute
home. For connecting to the SunSport connector, note that I used two
one-circuit connectors with part of the plastic housing cut off.
Charging the batteries using my homebrew charger and the "converter
piece" of wire.