Custom High power LED light bar

Wait, were you talking about normal voltage fluctuations of ~15v or +100v spikes?

You know, the more I think about the TaskLED drivers, the more I don’t want to use them, at least for now. The price for just the drivers is ridiculous, more than the LEDs themselves. I am gonna go with the Russian sourced units, I like how they set them up for modes, good price too. Sure, it would be very nice to have thermal shutdown safety built into the driver, but I can live without it for now. Everything will be interchangeable, so I can see in the future I will upgrade that part.

Voltage spikes shouldn’t be an issue, no. If you are worried, there are ways to stabilize the power, for both the electrical noise and voltage fluctuations.

Here are the optics that have come, the smaller elliptical TIR is a Carlco 30mm. The large lense is the 67mm Gaggione LLC56N, the one next to it is the 45mm LLC49E. The headlamp is an Armytek Wizard Pro V2, for size reference. Can’t wait to light those babies up with some xhp monsters.

I have purchased 2 of those drivers from Russia 2 days ago, one 3 amp model with 4 switch modes, and a 2.4 amp model with 4 modes as well. It might be a few weeks before I get them so hang in there. LEDs I was expecting this week, nothing yet.

What’s this mean? I might be interested.

Well, the more people who would buy at the same time, the cheaper the light bar will be, down to a point of diminishing savings… I think after about 5 or 6 light bars made the savings difference would be negligible. The CNC machining of the housing/case is the part that will make it cheaper with volume, this is what I am referring to. Also, I suppose the shipping costs for all the others part to be ordered will be reduced with volume as well.

Here is another pic, I made the elliptical lense, well, elliptical (horizontal lines on the lense face)… only it is 90 degrees the wrong tilt, I tried turning it in CAD, it allowed me to do it, but it just didn’t visually change. Not sure about that?

Might be interested, are the parts being machined in Canada?

Okay. Yes, the housing will be machined locally here in my home town. I am hoping he can machine the pieces for $150 each.

Possibly interested in this, pending the price. I've thought about the one I've wanted to build several times, and what seemed most appealing was XHP70s on the outside for flood, and XP-L HIs in the middle for some throw.

I love the beam pattern from the Ledil BOOM-wide (for the MC-E emitter), but I would probably go with the medium reflector for an automotive application so it's not just lighting up everything within 10'.

I would have to say 4000k would be my preference for automotive use, as well, possibly even warmer.

I missed your post here Prince. Price will be up in the $350 CAD at least.

I have been playing…I mean experimenting with the optics and the XHP-50 and 70’s and have come to the conclusion that the light bar will be exclusively XHP-50 candles. The spot on the 70 is too large and just wastes light (12 Degree FWHM), the 50 has a slightly more intense beam, plus it is a better 9 Degree FWHM, just right IMO. The drivers for the 50 can also power TWO 50 LEDs, the driver for the 70, only ONE LED.

Anyways, I will also be using the smaller Carclo 30mm Elliptical optic for near field flood.

Pretty settled on the specs me thinks:

8 XHP-50 J4 - 3x @ 100% drive current with 4 brightness levels (3A, 1.4A, 0.7A, 0.4A) 20,000 LED Lumens Total

4 spot optics: 9 Degree Beam, 90,000 Cd Peak beam intensity each = 360,000 Cd Total

4 Elliptical 30mm Carclo optics, 43 Degree x 19 Degree, 6800 Cd Peak beam intensity = 27,000 Cd Total… plenty for near/mid field zone

Just a little update, project far from dead, and specs MIGHT still change as it is far from done. Waiting for Cutter to bring in some J4 5000k 50s, and trying to get a hold of Conrad Heatsinks. I just ordered 4 30mm Carclo’s and 4 Gaggione 67mm spots. Will post some pics.

Just found this thread and I am interested. I’ve got a few light bars from rigid industries but this looks pretty awesome so far!

Looks great. I think I’m interested too. One thing that might be cool is a remote wireless switch, so control cables don’t have to be drilled through the firewall of the vehicle. I’ve seen lightbars like this, where all you have to do is connect to the battery, and done.

The Ford F150 has a spot made for this light

I think the XHP-50s are a good choice over the 70s. I’m not sure why I overlooked them previously.

Looks interesting. I would also prefer 4000k or warmer.
Most light bars have excellent spill (which is needed) but lack a strong long range hot spot.
If this becomes available in warm emitters and can accomplish both spill and hot spot, I’m interested.

4000k is easily doable if so desired. Subscribe to this thread for updates when i get the rough protype done, within a months time I think.

360,000 Cd in a 9 degree beam should be good 500m of clear visibility.

The xhp50 IS a great LED. Gonna post some beams shots here soon.

Btw, 4000k is the warmest you can go before the lumen binning drops off.

I’m good with 4-5000k temp. That would make for a nice temp when it’s snowy white here during our brutal winters.

how about this as a driver?
you can use one of this converter for each LED,
assuming you gonna use it as a 6 volt configuration. and assuming you want one mode (high all the time)
it could go up to 5 amper with hitsink, but 3 amper will do fine without.

I have the drivers set in stone for the bar, I won’t be changing that part unless I find something super special. They look a little too flimsy for my liking, the inductor in particular and I’d prefer soldered connections over screw terminals. Also yes, the drivers I have picked out have 4 current modes: 100, 50, 25, 12.5. Thanks for posting though, keep it coming, you never know. Anyways, the 30mm Carclo’s came in, (4 more of them), still waiting for the Gaggione, but those are coming from the U.S…

Here are a couple of quick beam shots from the 67mm Gaggione and the 30mm Carclo Elliptical. It is quite different to see next to no field with the Gaggione, just a nice even flat hot spot.

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I love it.

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Check out that hotspot!

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Looks really good so far. Keep up the good work. Nice and a needed application, we don’t need 50” bars to put out proper degrees of light. I can see these discretely mounted on bumpers, cargo racks or on a roof top remote control.

Glad this project is still alive.

How do you plan on switching modes?