Low-cost copper pills, spacers, optics, drop-ins (Updated 23/10/2022))

Hi, I’d like to buy
1 copper triple spacer for S2+
1 copper triple spacer for S2
1 copper triple spacer for X6
Please PM me!
Thanks

There is one more problem with X5 triple.
In stock it is assembled in this sequence: bezel-glass-o-ring-reflector.
If we save this sequence, we need to use full height pill (or small pill/spacer one extra part, short tube between head edge and o-ring).
The other way is changing sequence to this: bezel-o-ring-glass-optics.
What do you think?

Why glass? The tir lenses are meant to be used without additional glass…

Carclo quad lens are the same diameter, as hole in the X5’s bezel…

I think you made a typo here : S2 spacer
You wrote “This spacer will allow you to easily build your own triple XP-G2/Nichia 219/XP-L flashlight using one of the Convoy S2+/S3 (Not original S2). ” but it’s also written “Height: 13.4mm”

Corrected. Thanks.

kiriba-ru, for the quad mcpcb the wires come through a hole in the center. The heat sink/spacer would only need a center hole accordingly, and the emitter shelf in the light will need to have a matching hole drilled.

I use a center hole in the 32mm Noctigon for triples in the X6’s because it keeps the wiring safer. If the mcpcb is glued down, this isn’t so much a problem, but if thermal paste is used the mcpcb can twist when tightening the bezel and it will cut the insulation, grounding out the positive lead potentially and causing issues. I drill through the center pad (not needed) on the 32mm mcpcb.

No threads are necessary for the new style X6/X5 heat sinks, the sink is lower than the threads and the threads have a wider diameter than the area immediately above the emitter shelf. UNLESS you wish to make a full lens-to-shelf pill that encapsulates the optic in the X5, then it might be good to thread it in.

Edit: Images changed to reflect the quad, I had mistakenly posted pics of a triple

How do you imagine this? You are going to sell something with word “Yes guys, you need to take your unique copper head and drill a hole in the center”?

I would like to have X6 with 4 leds, when the central one is red and is blincking rarely.

I have made measurements by my own and I`m not sure you are right.
Upper edge of the thread is a bit (about 1mm) upper than the upper surface of mcpcb (when using carclo 6mm height optics) on X5.
Full height (lens-to-shelf) pill seems to have to much problems.
Low height pill can also be with threads ot without, but first one will be defenetly twice price of the second one.
I have not heard any ideas about o-ring disposition. If we move it between glass and bezel, our optics sits a bit lower.
But if somebody convince me that o-ring should be under glass (as in stock), I would offer him other variant with spacer+one more part - short tube, that will play two roles: directing optics and being lower plane for o-ring pressuring.
Using triple is also a good idea for me, but most members associate triple with 24mm convoy host and want bigger optics in 31mm head.

Even your design with ultra-low wall thickness (I`ll never make so) can`t improve standart watertight. Stock reflector have a step for o-ring, your variant requires moving it out of the glass. This motion moves optics and pcb down, maybe that`s why do you say that spacer is lower than threads location.

I don’t imagine it, it’s how they make the mcpcb for quads. Center hole for wire access only. No side holes. It is what it is.

35mm quad optics for the X6 are fine, but where are there any 32mm quad mcpcb? None that I can find. I use 4 10mm SinkPAD and build it by hand with careful placement, glue the star down with Arctic Alumina Thermal Adhesive. I built the first X6 triple, the first X6 Quad, the first X5 quad and probably the first X5 triple. I’m not saying my way is the only way, but I used what was available and made some adaptations as necessary. That’s why we call it modding. :wink: For the X5 in copper, I reflow the pill into the head when mounting emitters so the 32mm mcpcb, copper heat sink, everything… soldered into the light like one piece.

Ideally the light could be made to fit the triple and quad optics from the factory, with appropriately thicker emitter shelves as part of the light, integral, no spacer necessary. We’re working on that…

24mm optic falls through the bezel of the X5. No way around using the o-ring between lens and bezel. This is why I made the copper pill go all the way to the glass, so the o-ring could be at the top of the copper pill/spacer and the glass would press it to the sides, making the seal. It works. I’ve got 2 quads and a triple and I’ve built 2 other quads.

If putting the o-ring on top of the glass instead of under it moves the optics and mcpcb down, that is an internal spacer measurement that doesn’t affect the spacers relationship with the threads positioning in the head of the light. The X5 is not made in the same way as the X6 is.

I don’t doubt your abilities. I`m trying to make thing for both who have them and who don`t.
I haven`t say anything about X6 quad. X6 35mm triple or X5 24mm quad only.
You should see X6 spacer drawing in first post. I never tryed making side holes, the idea is to make straight central hole+mill grooves for wires. That`s the way to except host drilling.

On my triple heat sink/spacer, I cut the shelf for the o-ring just like the reflector has it, tapered and everything so it will press the o-ring against the sides even while sealing at the pill.

If making a more simple spacer to sit under the mcpcb, the threads could probably be utilized on the X6, maybe not on the X5, either way it wouldn’t really gain anything as the threads would be on a level with the emitters and the heat is coming out the bottom, into the original emitter shelf. This small light is going to have issue dispersing the heat of 4 emitters whether threads are used or not. So it’s not really essential to go to that length, that’s all I’m saying.

Seems we are hard to understand each other.
I have never thought about using quad optics in X5 without glass.
I can beleive you but standart sealing is much better. Reflector has step, this step with internal 90 degrees angle between glass and bezel side make the square closed so o-ring is surrounded by whole 4 sides, and when you twist bezel harder there is no way to go out for the o-ring.
Your variant have no lower surface for the o-ring and it can slides down.

You haven`t understand what I am writing about at all.
When we have bezel-glass-o-ring-tir tir is pressed to the glass which is pressed to the bezel. We don`t look at o-ring thickness when calculating spacer height (because o-ring is around upper edge of tir).
When we have bezel-o-ring-glass-tir we have the same, but o-ring between bezel and glass, that meens that we have +1.8mm to optics part what meens that –1.8mm to the spacer height.

This way is much better. But this is triple :smiley:

I am thinking about spacer that would be cheap and user-friendly.
If BLF members agree that threads are excess, let it be so.
But I don`t think that spacer should have flat top without pcb size. It is much simplier to position pcb, regardless you using thermal grease or solder it to the spacer.
If nobody oppose this and milled grooves for wires, one more question opened about o-ring place.
Stock place+extra tube will have some extra cost, but simplier way to assembly.

Made this afternoon. Same ramping shelf for the o-ring that the original reflector has. This time I threaded it, so it screws in just like the reflector.

Nichia 219C emitters, 2960.1 lumens out the front with an Efest Purple IMR14500.




Wonderfull, but how much would it cost?

I say this is something RMM/Mtn El may want to stock for us!

What say you?

(much pitchfork rattling and grumbling)

I see the #3 “Copper spacer for Carclo triple Convoy S2+/S3” is now in stock. I’ll order four if shipping to Sweden is reasonable. Prefer to deal with this here by PM or do you want me make an order on Ebay?

I’m no machinist, just got a lathe last September and have used it little over the winter. But even at that, and with no pre-measuring, I made this heat sink in just over an hour, much of that time spent taking a gazillion measurements. And I started out with a 1.5” bar to get the 26.3mm full outside diameter above the head.

Regardless, a hole has to be drilled in the emitter shelf of the light. The Dsche quad mcpcb has a center hole for wires. As does the Noctigon triple mcpcb.