DIY HID Flashlights

Written by wendy morgan
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DIY HID Flashlights
Save money by making your own HID flashlight. (flashlight image by AGphotographer from

Flashlights are a welcome tool for shining light into dark places, such as during power outages or camping trips. Unfortunately, there are times when regular flashlights just are not bright enough to shine very far into the darkness. HID lights are several times brighter and last longer, but can also often be costly. Make your own from an existing flashlight and a few extra supplies without spending lots of money.

Skill level:

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Things you need

  • Large flashlight that uses a 6V H3 Bulb
  • Soldering iron
  • 25-foot extension cord
  • H3 HID bulb
  • Small pieces of cardboard
  • Cigarette lighter plug
  • HID ballast
  • Large zip tie
  • Small zip tie

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  1. 1

    Open the flash light by twisting off the black ring around the bulb. Disconnect the black and white wires within the flashlight by unscrewing them at one end.

  2. 2

    Take out the wire holder that holds in the bulb. Remove the old bulb.

  3. 3

    Remove all the inside pieces from the flashlight by unscrewing the switch, taking out the charging port and the battery holder. Make sure to remove the rubber cover for the charging power as well.

  4. 4

    Take the battery switch and cut one wire, then cut one end of the power cord as well, stripping it back a few inches. Run the two black and white wires inside through the hole where the charging port was.

  5. 5

    Take the new HID bulb and put it in place of the old one, bending the wire holder around the bulb.

  6. 6

    Put the small zip tie on the power cord to keep it from slipping back out. Connect the spade connector from the harness that is connected to the HID bulb to the power switch and the red wire to the white wire on the power cord.

  7. 7

    Cut the black connector from the HID bulb harness, connecting it to the black wire on the power cord and covering it with electrical tape.

  8. 8

    Connect all wires from the bulb to the ballast. Placing the ballast inside the flashlight where the battery is, brace it on either side with pieces of cardboard to keep it in place.

  9. 9

    Reinstall the switch to its original position and replace the flashlight cover.

  10. 10

    Remove wiring and the rubber piece at the base of the cigarette plug.

  11. 11

    Run a knife around the opening at the base of the cigarette plug where the wires run in until the opening is big enough for the power cord to fit in. Put a small zip tie on this cord to keep it in place. Solder the black wire to the centre of cigarette lighter and the white wire to the top of the cigarette lighter.

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