Package arrived safely about 2 weeks ago. There are H04RC and some M200 samples.
Since my usual CNC workshop closed until we don’t know when, I’ve been designing/making manual jig for it. First light will start tomorrow. This jig is very critical for accurate MCPCB centering and those custom optic trimming
[Clemence]
PM sent.
What was usually a 3 days process (on CNC machine) now takes 2 weeks just for the jig making. I have to do everything manually using whatever I have in my workshop. I can’t even buy raw material. So I used aluminum scraps for the drilling jig.
[Clemence]
I am not sure what the above photo is,but it is a beautiful site to see 
Thank you for the update, Clemence! You are extremely resourceful. With the lack of tools and workshop access will you still be able to precisely place the optic to maximize efficiency as well as precisely build other parts?
To answer all those questions from this forum and emails. Yes, In fact, I can boast my OCD-ness by work from home in my own workshop. With my friend’s CNC workshop, I can’t always interrupt the operator’s work.
This mini milling machine has XY accuracy of 0,02mm and Z accuracy of 0,025mm. Cutter holder used are ER16 and ER32 collet with 0,008mm run out tolerance. Good enough for me.
This is why I spent great deal of time making the work piece jig: repeatable batch MANUAL processing
Those who familiar with tapping small screw threads will appreciate this work. A pitch perfect rolled thread (yes rolled, not cut). I know it’s just a common M2x0,4 screw thread, what’s so special about it? Take a look closer…
Two screw threads are precisely located within 0,01mm accuracy. They were carefully chamfered for flareless screw threads. And the most important thing is they are made unusually deep (3,25mm effective threads!) for such a headlamp, with very close fit tolerance. I made this because most BLFers who bought these H04RC would change the MCPCB often. Deep screw thread makes sure you can get enough clamping force to secure the MCPCB and lessen the thread failure.
[Clemence]
Many thanks for the update Clemence. Can we order a few extra screws from you with our orders? Especially for those of us who will have difficulties obtaining them locally. Thanks.
Very impressive, nice to see such attention to detail.
Sure I will include a pair of extra screws in each set.
[Clemence]
Hi Clemence, just wondered if the original optic will also be included? I need to replace my H03 optic and was looking to buy one from Yajiamei but suddenly realised there’s no need if you’re going to include the original optic with each light.
The original optic is exactly the same as suppled version, except the base is trimmed to fit quadtrix E17A/E21A. There are a total of 3 optics: 20°, 45° (same as OEM H04RC), 70°, and 30°x 60°. Note that the listed angles are used for identification purpose only (OEM spec), the actual beam angle is much floodier than that. I don’t plan to include the original untrimmed optic for safety reason. Untrimmed, the OEM optic will destroy the quadtrix.
[Clemence]
UPDATE 200703: Progress….
Just to give you the idea of how slow the process goes:
[Clemence]
I’m sure we all appreciate the attention to detail you’re putting into it. Thanks for the updates on your progress!
The value of craftsmanship of each light will last forever.......Very lucky to have Clemence in BLF......
seems not enough quantity to make a special MCPCB for it?
would also save a lot work on reflow applying paste and pick and place robot to a whole tray of MCPCBs
Yes, too few for a dedicated MCPCB. Reflowing is not as hard/time consuming as you might think. I don’t use solder paste with these, because no In100 paste available anywhere.
[Clemence]
Looking good! Are those in the boxes the ones you have done or ones you have left to do?
I work in batch. Those 101pcs in the box are tapped head unit. Only MCPCB and soldering left to do.
[Clemence]
Thanks for the update. Looking good. 
UPDATE 200712: Progress
[Clemence]