In post #1451 and #1532 I modded a very small AA zoomie with a dedomed XP-G2 S3 3D and a 15mm Bistro-driver. It worked very well and I got 41 kcd throw out of the tiny 18 mm lens. I liked it so well that today I did the exact same mod on a Cofly AA zoomie, that is almost as small but has a bit wider lens: 21.2mm, that promises 21.2sq / 18sq = 1.39 times 41 = 57 kcd, assumed that everything else equal which is seldom the case.
Here’s the zoomie:
I used again the 15mm Oshpark board that was designed by wight ages ago and reflowed the components of a Banggood Bistro-driver, except the FET, that is too big, I used and LFPAK33 FET from Mountain Electronics. And again the driver works well, not every combination of board and components is blessed, but this one just works!
For clamping the driver into the aluminium pill, my trick is solderering a small solid copper wire into a ground-ring-via near the FET, bend it over the edge of the board to the other side and then solder everything in, then filing it to shape. This wires sticks out when pushing the driver into the pill with a vice, the driver is now well fixed to the pill, and it has good electrical contact.
The led was reflowed on a 16mm Noctigon and dedomed while still hot. This host requires no thinning of the Noctigon, luckily the focus is correct with full thickness of the board. I glued the board in with Arctic Alumina Adhesive and soldered the led wires. Then with a permanent marker everything around the die was blackened for an artifact-free beam.
The switch received some attention too, I did not trust the stock switch with 3.5+ amps of this mod, neither its resistance or that it will not fail. I have no pictures but with a hacksaw I sawed a slice off the aluminium switch housing, widened the opening with the drill-press and sanded it nice and flat, that was the new retaining ring for a standard 16mm switch-board with small Omten (spring bypassed). The boot cap was replaced by a thinner 6mm height blue one, so the light tailstands now.
It is another very succesful mod, first the tint is again very pleasant neutral ~4000K, and the rest: on a purple Efest 14500, 30 seconds after switch-on, the output in flood modus is 560 lumen, in spot 260 lumen, the throw, measured at 7 meters, is 58 kcd, almost exactly as predicted. For reference: that is over the stock throw of an un-modded Jacob A60