Which bit are you drilling out to 1â? The reason I ask If your drilling out an existing hole that is to large and the wall thickness thin the drill bit may well grab. A rotary burr would work better if this was the case.
Too COOL! What a great idea, going to be one heck of a search light! What are the dimensions of the stock reflector? Pics of the reflector?
Way to go Enderman! :+1:
The largest hole in the back of the handle, where the old plug used to be.
I measured it and there should still be several mms of aluminum on either size to keep it strong.
The reflector is 4â diameter, hereâs one of the pics Will sent me:
I have been so busy modifying the handle that I havenât touched the main body of the light more than once to test if it works 
Iâm glad you like it, good to see it being in hands of someone who will put it through real use! 
I never thought there would be anything in the tailcap, judging by the components perhaps it is a LVP circuit?
What a cool project!
What is the size of that reflector?
Do you know where it was used Will?
PossiblyâŚ
Iâm not sure if HID bulbs and ballasts get damaged if running at low voltage.
Thanks 
91mm reflector inner diameter, 104mm head diameter.
Only a few mm bigger than the TN42
What a great host!
Have you though about the new XHP-50.2? It will probably reach the same brightness as the XHP-70, but with twice the Candela.
Concerning the XHP-70. I would go with 9A, much less heat and basically the same brightness.
The 50.2 is still several thousand lumens below the XHP70, even if I overdrove it maybe I would get 4k lumens over 9mm^2, which would not be much more intensity than the XHP70 at 6k+ lumens over 16mm^2.
Less brightness, similar cd, not worth it. When cree releases a XHP70.2 then I might upgrade, but for now the XHP70 P2 1C with a shaved dome is what I will be using
Also, the XHP70 is running at 12A because itâs what was available on the driver I bought.
If you look at this graph, you can see it peaks at 12A.
It seems like the difference between 9 and 12 is not much, but
- this is N2 bin, not P2 which is much higher, and
- this is with worse cooling than I use on my flashlights.
The tests done by djozz and other people is just on a piece of copper or small heatsink, since thatâs similar to the cooling you will get when putting the LED into a regular flashlight.
I always go overkill on the cooling for all my projects, so that curve in the graph will actually not curve down so soon.
What makes it curve down is the heat. This is from djozzâs test:
12A 0 seconds 6631
12A 10 seconds 6258
12A 20 seconds 6164
12A 30 seconds 6024
12A 40 seconds 5838
12A 50 seconds 5744
12A 60 seconds 5557
As you can see, when the LED is running at good temperatures you get much higher output.
I would not count out the XHP-50.2. I just checked with the Cree PCT. In K4 Bin it has the brightness of a XHP70 N4 (the bin below P2) and actually has a lower Vf compared to the XHP-70 (usually means that it should take even more current).
XHP-70.2 should be amazing 
Where are you getting your numbers??
The XHP50.2 K4 is rated at 1380lm max while the XHP70 N4 is 1830lm max⌠(at 85C, and their rated voltage+current)
http://www.cree.com/~/media/Files/Cree/LED-Components-and-Modules/XLamp/Data-and-Binning/dsâXHP502.pdf
http://www.cree.com/~/media/Files/Cree/LED-Components-and-Modules/XLamp/Data-and-Binning/ds-XHP70.pdf
Also it doesnât mean you can just pump more current through the chip. Typically you can drive them at 200-300% their rated spec, which is how you can get 4-6k lumens out of an XHP70.
If you do 200-300% of the XHP50, you would get 3-4.5k lumens.
The current increases exponentially too, so even if you were able to drive it at 400% without it dying it would be using way more current and producing more heat than the XHP70.
The XHP70 is the best way to get high lumens from a small area. The only thing close is the luminus LEDs, but those need special drivers because they use like 20-40 amps and low voltage.
Other options to get high lumen output involve COB LEDs, but I would rather not use that in this light because I want useful throw, not just flood
Daleâs L6 @ just over 12 amps measured 7141.5 lumens at start up! There is no chance in hell that a 70.2 will out throw a P2-1C, maybe a bit more lumens, maybe, but never out throwing it!
The 70.2 will be the same as the XP-G3, L.2, 50.2 No throw high lumen crap! :person_facepalming:
Go ahead try to de-dome any of them, you know what you will get, even worse crap!
But you CAN de-dome a XHP70 P2-1C!
Itâs going to one bad boy there ENDERMAN! 
Haha nice
Youâre right, a .2 probably will be more lumens less throw since I canât dedome it, the g3 was a pretty big disappointment.
Who knows though, maybe if the lumen increase is high enough I can deal with a bit less throw.
8k lumens maybe?
This is supposed to be a more practical reflector âflashlightâ with spill and lots of lumens, I already have a crazy throw flashlight!
The P2 1C I have is shaved-dome though, I will not be dedoming it because I want to have some protection over the dies since I often drop or touch them accidentally xD
Still should get over 6k lumens which is already 2x more than the Hellfighter HID lamp does.
This afternoon I will be trying to get that last darn screw out, once that happens I can start installing my Neutrik plug.
Even though itâs still not converted to LED I would love to get it working and take it out for some pics with the stock HID setup!
You can seal a dedomed LED with high temperature clear car laquer
So far I have done the P2-1C TN42 with dome on, shaved and de-domed, and changed the FET to a SIR404 shortened the 18awg leads till their banjo string tight and running 4 VTC5Aâs right off the charger, getting 12.82 amps on the hit, so now Iâm trying to figure out how to stuff 4 of my 20700A Panyâs in it! :person_facepalming: Itâs never ending!!!
So Iâll be watching, canât wait to see the results, in the meantime I have a few more of these things to mod for my Buddies!
:smiling_imp: :+1:
Nice collection
When finish this hellfighter should perform like one of those TN42s modded with the XHP70, but with better cooling so it can run continuously at 12A.
btw I finally managed to drill the darn screw out, it took a few hours of work, but I got the hole rethreaded and now can attach the light back to the handle!
Next step is to widen the back hole to fit the plug.
Yeah man, they get crazy hot in Turbo, but not bad outside and 6 levels. Really need some kind of active cooling system, got the room in there?
Yup, plenty of space inside.
I would rather not have a fan though because that would mean cutting vents into the beautiful aluminum body, so what I will try is using multiple thick heatpipes to transfer heat from the LED to the body and radiate it that way.
Selfishly I would love to see a backpack liquid cooled system! Haha that would be something else.
Haha thatâs definitely possible, battery and cooling in a backpack, only LED and reflector in the light
Some day I will build that, although not soon cause I have no money :C
Youâd be a true Ghostbuster!