Hello my BLF family!
In THIS thread “djozz” was curious about my mod so here it is!
I’m sure that lot of you know that Ultrafire 602C is one of the smallest clicky hosts in 16340 battery format that you can buy around. I’m also sure that majority of BLFers much appreciate tint and CRI of Nichia 219A B11 so I gave myself “challange” of building one with single 219B R85. After short period of time I wasn’t entirely delighted with finished product so I had an idea (inspired by “comfychair” ) of cramming three of older 219A B11 emitters together with TIR optics in the exact tiny host that previously carried single, newer emitter. Realization of this idea requires major modifications of over-sized parts that I planed to use in “unsuitable” host .
The 602C host from Fasttech comes with 18mm reflector with medium “orange peel” texture designed for XM-L sized emitter, standard 18mm glass lens, O-ring between “head” and lens, assembled switch assembly with genuine Omten 1288 reverse clicky, green GITD (Glow-In-The-Dark) silicone/rubber switch boot cover, aluminum “pill” that accepts 16mm MCPCB-s with brass insert for 17mm drivers and one insulation gasket.
Parts used in this build are: Noctigno 3XP MCPCB , QLITE REV.A with 2 aditional AMC7135 (350mA bined ones) , Kaidomain-s triple nichia w/ TIR optics , 20mm AR glass lens and 22 AWG silicone, silver plated copper wires
Mind that all photos were taken afterwards.
I’ve started with removing “lip” of the pill in order to have flat surface for Noctigon 3XP MCPCB. Second step of modding the pill was drilling hole in the center for wiring. After that I’ve removed/sanded sharp edges caused by drilling with xacto knife and 800-grit sandpaper. I’ve also polished surface to mirror finish with polishing paste after sanding surface with 1500-grit wet sandpaper.
Done with pill.
Second part was grinding/filing/sanding (in that order) 3XP MCPCB and TIR optics from 20mm to about 18.5mm, maybe a bit more (I didn’t owned caliper during this process). Grinding was done with hand cranked stone grinder, finishing touches were done with 1500-grit dry sandpaper. The only problem that I’ve encountered was fact that I didn’t have any type of gloves so there is few fingerprints on inner part of the optics. I’ve try to clean that with some kind of “window washer” in trigger spray bottle, kinda succeed (few fingerprint marks have left). Kaidomain-s optics doesn’t fit into Noctigon 3XP MCPCB because 3XP is designet do accept Carclo optics ( narrower “legs”) so I widened leg-openings with Dremel in order to fit “unsuitable” optics. I’ve also needed to make spacer between MCPCB and pill because whole pill assembly is too short for proper water sealing. I’ve made spacer from copper pipe ( I’ve flatten it, filed it down to 18.5mm, sanded it and polished it to mirror finish).
Third part was hardest and most dangerous. In that time I’ve had 18mm and 20mm AR lens from IOS . My idea was to file down the bezel in order to have better output efficiency and desired beam profile, thus 18mm lens were too narrow so I made decision to grind (narrow down) 20mm lens to “best fit” as possible. Grinding was also done on cranked stone grinder. That was really messy and dangerous job because small glass particles were sprinkling everywhere and I didn’t wear any eye protection whatsoever (yeah, I know, safety first :8) ) and one of the glass particle sprinkled into my eye. Luckily, I’ve escaped permanent eye damage . In the end I’ve succeed in my intention.
Fourth part was reflowing emitters (reflowing is done with hot air and soldering paste), driver assembly with two additional 350mA bined AMC, removing stock wires from driver and replacing them with 22AWG ones, shorting fourth star to the ground in order to have moonlight/firefly mode. I’ve also improved/reduced spring resistance (added soldering wick and copper cap on top of the switch spring).
Fifth part was one of my classic way of adding uniqueness to my modded Flashlights/Hosts - heat-spreaded transition.
IT WORKS!