This option will be the most cost effective and easiest to assemble with basic tools. It’s adaptable to whatever size, shape, or style of headlight you decide upon and if needed you can tailor the output level and pattern as well.
To calculate the potential output of the array you are going to make take the rating of the LEDs (6000mcd = 6 candela = 6 lumens) then multiply by the number of LEDs you intend to use.
If you want even more intensity from your LED headlight you can add a High Power LED. These are available in outputs ranging from 100 to even 600 lumens! The LED I chose is a Luxeon Endor Rebel rated for 430 lumens at @ 7.5 watts.
I used 20 of the 6 lumen LEDs, so 20 x 6 means my output is approximately 120 lumens.
If you want more intensity it’s best to start by using LEDs of a higher rating. Also keep in mind that even 6,000mcd LEDs will be painful to look at directly in the dark and will need to be diffused somewhat.
You can diffuse LEDs
1. by sanding their lenses with 600 grit sand paper
2. by making a soft diffusor sheet out of 1/16th or 1/8th inch clear or tinted acrylic or polycarbonate and then sanding it with 600 grit sand paper
3. by making a heavy diffusor plate out of 1/16th or 1/8th inch thickness white polyethylene sheet
Part 1 Supplies
1. Headlight fixture
2. Thin Polycarbonate or other suitable plastic sheet
3. Bulk lot of 50 to 100 white LEDs in 6000mcd or higher
You can order these cheaply from Chi-Wing LED Product Shop
4. Resistors (180ohm 1/4w for 13.4v max input or 220ohm 1/4w for 14v max input)
5. 22ga Wire
6. Pack of full sheet label paper
Part 1 Tools
1. 45w+ Soldering iron
2. Wire cutters
3. Power drill
4. Tin snips, band saw, or scroll saw (tool for cutting thin plastic)
5. Super glue
6. Hot Glue (optional)