Light talked about and reviewed here in this thread .
I was able to make a pill/heatsink to fill the gap under the star/led. This was my first attempt at making something like this. I made it out of spare/scrap aluminum belt idler from the machines I service at work.
On my 4th try I finally went to our main shop where we have a drill press, belt sander, press, torch and other tools at my dispossal. This was alot easier when you have the tools that you need for the job. I first squared the end of the roller on belt sander. Then put the roller in the end of a cordless drill so that I could use sandpaper to sand down the outter diameter to the desired size (22.6mm). Then cut it to the desired length (12mm). Where the idler rides on a shaft with bearings there was a hole in the middle (11mm). I filled the hole with random wire that we had laying around the shop and solder. Started heating it with the propane torch and started adding solder to fill in the gaps, worked like a charm. Then cut off the extra wire and put it back on the belt sander to make it flush again. Used a triangle file to cut some notches in the side for the wire from the driver to the led to slide through. Tried to press the pill/heatsink in and it was a no go. Finally i used sand paper in the gap in the torch body to get it to the right width. Was able to press it in then. VIOLA
Here is what I started with
Just after cutting
Sanded smooth
Wire crammed in along with solder - heating it up and adding solder
about to cut off the wire that has been added to the pill
wire cut off and sanded smooth, still needs filling up. Heated again and then filled it with solder
Filled and sanded smooth and notches cut into the sides
heatsink pressed in and smoothed out
Upclose white wall beam shot
I am satisfied with this mod and it now pulls the heat away from the led. The section of the light that was modded is probably double the weight it was. It gets warmer faster then it did before.
Sorry for the pics not being great all I have is my Iphone 4s to take the pics
reserved - tried to put a XML U2 in it and it was a failure pics coming either tonight or tomorrow.
Here are the pics - The problem was it was not as bright and had a odd beam and hole in the middle. Kind looked like a 4 die pattern like an MCE maybe or like the XML easywhite 12v and 6v versions. Dont know why it would do this. I swapped back in the orgional led and it was fine again. :~
blurry pic put it is a 14mm XML U2 sent to me by AlexGT
This is the weird beam it made! What could be the reason?
Great job! It's always fun when you can do something yourself with some ingenuity to improve a light. You'll feel more of a tie to the light as well since you've added your touch. I hope mine turns out as well. I don't understand why the emitter swap didn't work. Did you damage the U2?
Thanks Garry, I hope yours turns out good also. You are right that about light, will probably want to use it more then usual. Now I just need an upgraded driver or either a 26650 battery. Where did you get your 26650’s at
Not that I know of, but who knows I have damaged things before. Have you ever seen a beam with a hole in it like that?
I have King Kongs raised top INR from Int'l Outdoor. They fit my light just fine, but beware that the raised top ones may be too long for some lights (i.e. Cyclone C88). I've not seen a beam like that before.
. Why was the led swap a failure?