I'm turning this light into an XM-L light, with a NANJG driver.
Here's the components that I need, besides the kit in the original post.
XM-L T6 3C led on 16mm star, NANJG 105C driver and the missing isolator from the kit.
Looking at the driver end of the pill, I see there is about 5mm of air space below the driver seat. I know my driver is thin, so I should be able to get a little copper in there, to help with the heat.
These are copper rounds that I bought on Etsy. They are 20ga x 5/8" round and they are too big in diameter, but I will take care of that shortly.
Looks like the driver would take up about 1.5mm of depth, when it is in the pill.
The three copper rounds will take up about 3mm or less in the pill.
I put 60/40 rosin core solder on two of the rounds and I will solder them all together.
I use whatever is handy, to press on the hot rounds, to squeeze excess solder out of them.
Since the 5/8" dia rounds are too big, to go down in the pill, I just use a file to take off the outer edge a little. I have done this stuff so many times, I don't measure any more, I just do it by eye.
Here's a way to do it easier and get it round. Use a marker to just blacken the edge a little, all the way round and then use the file to remove the black. Do that till the piece fits in the pill. It's easier than "doing it by eye."
Here's the finished copper insert
Side view shows that there really isn't much solder in between layers, so it's all good and will take heat fast.
How it looks in place. I still have room for the wires to fit in between the driver and the copper. The pill weighed less than 1 gram before the copper. Now it will weigh over 6 grams. Not a lot, but definitely an improvement.
I marked the holes for wires, using the pill as a pattern and I am ready to mark them with a punch, prior to drilling.
The finished holes and a sanding block takes care of any rough spots, from drilling.
I have applied solder to the star and to the wires.
The star is now ready to go into the pill. I use AA (Arctic Alumina Adhesive). I will glue the star and also the copper heat sink in place.
Any more, I find a socket that will work to hold the led down to the pill and clamp it all on the bench.
I do the same with the Copper heat sink.
I always have ground problems with these tiny pills, so I have gone to wrapping a piece of wire through one hole in the driver board and that makes it a hard press fit into the pill. It hepls to make contact.
Then I solder the wire at the edge, to make sure I have good ground. The pill is done and ready to test out.
I had to cut down the isolator to the diameter of the reflector, so it would clear the top of the pill, when the pill screwed in.
Here's everything in place, in the head.
From the top.
Here's the size of the light in my hand. It's small enough for an EDC.
It has three modes, hi/med/lo and I could only test by holding up two AA Alkalines to it, with a wire. I don't have any 14500 batteries, but from the length, I know it will only take an Unprotected 14500. A Protected will be way too long for this mod.
That's it...
BEAM SHOTS.
ISO 100, F:2.7, Daylight WB, 1 second shutter speed. Both shots.