OK, I finally figured out how to post pics here so......here it goes.
So I had this idea stuck in my head like a bad song and had to get it out. Watching Old Lumens' videos and reading his threads inspired me to give this a try. (Thanks OL!) I started off trying to fit copper plumbing caps but none would work. I then decided to to do what OL would do, I cut a 3mm band from a copper cap and wrapped it around a socket from my tool set to get the diameter I needed and then soldered it together. I then trimmed the flat part of the cap to fit the bottom and solder it to the ring. I also cut a rough cube of aluminum for added heatsink mass.
I then used my dremel tool to shape the aluminum into a cylinder and notched it so the wiring could reach the driver.
Test fitting the aluminum half of the heatsink in the head.
Test fitting the copper half.
Here it is mocked up with the factory 12.5mm board, not good.
Here was my first version of this. it was an XP-G HCRI emitter on a 14mm board. Better but not quite right.
After all my parts finally came in.........I stripped it back down.
I decided to use texture paint on the visible part of the heatsink and then clean up the mating surface.
I then used a socket to press the new 16mm board with Nichia 219 into the heatsink and some weight to hold it until the Arctic Alumina Epoxy dries.
I then soldered the leads onto the boards pads.
This time around I filled the head partially with thermal compound, added the aluminum half of the heatsink, added more compound and then routed the wires through the head as I pressed the copper half of the HS into the head. I then soldered the leads back onto the driver.
I now have a variable output 92+ high CRI and VERY useful flood light.
Thanks for looking,
Jamie
