These Duracell headlamps have a plastic "spring" that is part of the back plate. Over time, that plastic spring will break, leaving you with a floppy headlamp. The fix used here is to bend a paperclip in various ways through the back plate, so that the paperclip acts as the new spring.

Supplies

Necessary:

Vice grips
Pliers
Wire cutters
Large paperclip

Optimal:

Two pairs of vice grips
Pliers
Wire cutters
Large paperclip
Small curved needle nose pliers

Step 1: Remove Strap and Back Plate

Remove strap and then remove the back plate with curved needle nose pliers by bending the mounting point out toward you while moving the headlamp out of the mounting hole. Make sure to grab as much of the mounting point as possible (as shown in the picture) so you don't fracture it. Keep in mind, this shouldn't require much force at all. It should be really easy.

If you don't have curved needle nose pliers, you can remove the backplate with your hands, but it's difficult. The first time I removed the back plate I used my hands and ended up cutting myself, so be careful if you do it this way.

Step 2: Retrieve Paperclip

Retrieve a large paperclip. It doesn't need to have a coating on it, but it's preferred.

Step 3: Bend the Paperclip Into an Arch

Bend the paperclip into an arch.

Step 4: Weave Paperclip Through the Two Middle Holes

Weave the paperclips through the two lower middle holes.

Step 5: Weave Paperclip Through Next Hole

Bend the paperclip up toward the next hole, grab it with vise grips and pull it through the hole.

Step 6: Flatten Middle Arch

Flatten the middle arch with the vice grips.

Step 7: Start Creating Spring Shape

Bend paperclip downward. Then, in relation to the square opening, grab the paperclip so that the next bend will line up with the middle of the opening. Now, bend the paperclip upward 90 degrees.

Step 8: Cut Paperclip

Lightly bend the paperclip until it touches the top of the mount. This gives an indication of where the paperclip needs to be cut.

Now cut the paperclip a little below where the paperclip and mount met.

Step 9: Finish Spring Shape

Bend the small portion toward the mount. It should stick out slightly so that it will apply some pressure against the gears on the headlamp. If the original plastic spring is still attached, now is the time to break it off.

Step 10: Perform Steps 5 - 9 on the Other Side

Perform steps 5 through 9 on the other side, but use vice grips to hold the existing paperclip arches down.

You can see how the first spring made (the one on the right) is nicely centered in the opening. The one on the left is not, though it'll still work.

Step 11: Reattach Back Plate

Hold the back plate against headlamp and make sure the new springs line up on the gears. Attach the back plate by pressing both sides down simultaneously.

Step 12: Test the New Springs

Test the new springs by moving the plate back and forth. If there's not enough spring tension, remove the back plate and rebend the paperclip springs.

Step 13: Reattach Strap

Reattach strap.

Step 14: Say Goodbye to the Floppy Headlamp

Sayonara floppy headlamp!

Introduction: Duracell Headlamp Spring Gear Fix