So, here's the video with the final assembly and beam shots.
Now, here's the runtime test:
Starting at 7:20PM using a set of AA Eneloops that were fully charged almost 2 weeks ago.
(Note: By saying "no change in brightness" I mean no noticeable change to my eyes. Obviously it changes from the moment it is turned on, but my eyes did not notice enough change to note it.)
7:20 turn on
7:30 no change in the brightness - slightly warm to the touch at the base of the head where the heatsink is.
7:40 no change in the brightness - warm at the head and on the top of the body near the head.
7:50 no change in the brightness - warm all over from top to tailcap.
8:00 no change in the brightness - noticeably warmer to the touch, but still ok to hold, sort of like a hand warmer on a cold day.
8:05 slight change in the brightness - heat is the same
8:10 more noticeable change in brightness (estimate 30% less than when first turned on) - heat is the same or less.
8:20 down to 50% estimated light from turn on, still useable for a sidewalk or bright room light - body is cooling off
8:25 very dim, estimated 25% of light from turn on - heat is no longer an issue, it's cooling off fast.
8:30 it's a night light now
8:35 I shut it off. I don't want to drain the eneloops to nothing, but the light left would be about like a keychain light.
Conclusion: Amazing!! 1 Hour to get down to 50% from start up! Over 1 hour of continuous useable light! Heat was never any real issue and it could be handheld all during the run! Although at 15-20 minutes I might switch hands, but never hot enough to make me want to let go or worry about it.
What mods did I realy end up doing?
1.- Replaced the plastic lens with a glass one.
2. - Replaced the plastic reflector with an OP aluminum one.
3.- Made a new Heat Sink.
4.- Added the Cree XM-L T6 emitter
5.- Painted the light
That's really it, since I am not counting the mods to the tail cap switch, the battery holder or the circuit board. I had to undo all of that when the board turned out bad. Lot's of work that didn't need to be done. In fact most of it didn't have to be done. It was for the enjoyment of doing something and now it's up for sale.
I would say I easily sunk $60 into this project and if I were really to add it up, it would be more like $75.00
Not a budget light!
Conclusion: Overall the mod came out well, but I would not recommend this light for someone who just wants a drop in. The dimensions of the light fall into the "either too small or too big" category and you probably will not find the proper size Lens, Reflector or Heatsink. Those parts have to be modded to fit. Also, for all it's hype, the T6 isn't really spectacular. It's in the same range as the P7 and MCE. It's just newer and has less Vf and better efficiency. If you own a P7 you won't notice the difference, if the T6 were in the same exact light.
What I was very happy about was the runtime! The best runtime I have seen in a high powered 3AA light. Emitter efficiency has something to do with that, as well as how well the heatsink is taking care of the heat and of course the Eneloops are a big plus factor. Gotta love those Eneloops.
Parts List
SAiK SA-305 -DX - $14.99 free shipping
http://www.dealextreme.com/p/saik-sa-305-cree-q2-wc-3-mode-140lm-white-led-flashlight-3-aa-42672
41.5mmx18mm OP Reflector -DX - $3.99 free shipping
http://www.dealextreme.com/p/aluminum-textured-op-reflector-for-cree-mc-e-led-emitters-41-5mm-18mm-17385
46mm UV Lens -Ebay $1.99 free shipping
1-5/8"x1" Aluminum Round Bar for heatsink -Local - $5.00
8X7135 Selectable Mode Driver -Illumination Supply - $6.75 shipping additional
http://illuminationsupply.com/8xamc7135-28a-selectable-mode-driver-p-45.html?zenid=4676dce30735a9c717a7d777646ac022
Spare 7135 Chips -Illumination Supply - $0.50@ shipping additional
http://illuminationsupply.com/amc7135-bare-sot89-package-p-71.html
Cree XM-L, 12.8mm Round MCPCB, T6, 1C tint -Illumination Supply - $9.00 shipping additional
http://illuminationsupply.com/cree-xml-128mm-round-mcpcb-t6-1c-tint-p-34.html
Other Supplies
Arctic Alumina Adhesive -NewEgg
Arctic Silver Ceramique Paste -NewEgg
Loctite Anti Seize Compound, Silver -Drillspot
http://www.drillspot.com/products/550057/loctite_38181_silver_anti_seize_compound?s=1
Copper Wire -Local
Copper Sheet (Small Pieces) - $5.00 to $8.00 with shipping in price
http://www.etsy.com/listing/84801198/solid-copper-sheet-sampler-26-28-30
http://www.whimsie.com/coppersheetwire.html
http://www.objectsandelements.com/shop/sheet-metal-copper-sheet-c-73_74_76
Teflon Wire -Ebay
Paint - Local Hardware Store
Krylon Crystal Clear
Rustoleum Textured Metal Paint