How small are you? 3- mode Solitaire, some beam shots

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Rufusbduck
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How small are you? 3- mode Solitaire, some beam shots

I like coming up with new ways of using 7135 drivers in Maglites. Recently, I removed the 7135 chips from a board, cut the board down added 3 chips back and installed it sideways in a AAA Minimag. I like the Solitaire mods I do but wanted a driver with modes, memory, and low voltage warning and while staring at one of the drivers noticed that on some versions  all the other components fit in a 10mm circle. Since my solitaire mod already stuffs the 7135 chips into the narrow section under the threads I thought I might try for a bit more by removing ~3-4mm from the tail cap to give me the space necessary for a newly altered board. I still need to bring the positive through to the led and now need to connect the Vdd pin of the IC to the 7135’s and make sure ground remains connected to the IC, the resistors, the memory cap, and of course the 7135’s.  I haven’t decided where the ground contact plate will go but since this will be a 3-chip Solitaire, I will be adding my brass bling to it. Run time on high will be limited by heat rather than battery life but at 1C, med should be around an hour and 5%low around 7 hours without heat issues for either.   Since the 16mm sinkpads aren’t ready yet and I don’t want to cut a 20mm board down that much I will be doing the DIY version of drilling through an Alu star and copper disc and soldering a piece of edit awg12 (used 14 instead on xpg pad) through both to the center pad of the led. This worked fine.

Three Tanna leaves to give him life, nine to give him movement. But what if he eats the whole bag?

Scott

Edited by: Rufusbduck on 04/10/2013 - 05:53
jacktheclipper
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Steve Martin .

You sir , are old .

Laughing

Tell us more .

MRsDNF
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Rufus get off the pain killers. Your not making any sense. I know what its like and there is help out there. There was an aussie band the Angels that had a hit with the dogs are talking. Does this set of alarm bells?

 

djozz quotes, "it came with chinese lettering that is chinese to me".

                      "My man mousehole needs one too"

old4570 said "I'm not an expert , so don't suffer from any such technical restrictions".

Old-Lumens. Highly admired and cherished member of Budget Light Forum. 11.5.2011 - 20.12.16. RIP.

 

ChibiM
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Pics?

Rufusbduck
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Age, pain killers, and pics. Yup, nope, and definitely but hard to take pics of an idea. Going home tonight where a board or two will pay the ultimate price for my delusions.

Three Tanna leaves to give him life, nine to give him movement. But what if he eats the whole bag?

Scott

Rufusbduck
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No pain killers. Just some good wine and I’m on my way.

I got started this evening by first removing the led wires and then the 7135 chips(I clamp the board down, place a line of solder across all three pins, when that melts I slide the chip off the board).

With the chips removed and before I do any more I wanted to check which IC pins go where as well as the resistor and capacitor connections. With those noted its time to cut. >)

The cutting took only a few minutes but carefully sanding the board down to a circle took about an hour. I used a bit of brass tubing as a guage.

And here it is cut And filed along with some other bits for scale.

And the bottom cleared for action.

That’s all for now.

Three Tanna leaves to give him life, nine to give him movement. But what if he eats the whole bag?

Scott

MRsDNF
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Wow. You've got my interest again even though I only think I know what you are doing. Keep that wine going so we can see some more. Cheers.

 

djozz quotes, "it came with chinese lettering that is chinese to me".

                      "My man mousehole needs one too"

old4570 said "I'm not an expert , so don't suffer from any such technical restrictions".

Old-Lumens. Highly admired and cherished member of Budget Light Forum. 11.5.2011 - 20.12.16. RIP.

 

djozz
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It is too small to fit and too small to even see what you are doing, subscribed Cool !

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You have probably have a great way to get the 7135's in the light (and who am I to mind your business)  but this simple driver (from dx) has three of them nice closely packed on a 15mm board that could be sanded down and might fit inside a solitaire:

Rufusbduck
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djozz wrote:

You have probably have a great way to get the 7135’s in the light (and who am I to mind your business)  but this simple driver (from dx) has three of them nice closely packed on a 15mm board that could be sanded down and might fit inside a solitaire:


Thanks, that’s a nice small driver but even sanded its still too big for a solitaire. I make a stack and use them without the board stuffed up into the narrow section formerly occupied by the “switch”. With just a little sanding it would fit a AA Minmag though.

Three Tanna leaves to give him life, nine to give him movement. But what if he eats the whole bag?

Scott

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Rufusbduck wrote:
Thanks, that's a nice small driver but even sanded its still too big for a solitaire. I make a stack and use them without the board stuffed up into the narrow section formerly occupied by the "switch". With just a little sanding it would fit a AA Minmag though.

ah, a stack sure beats this, you can't get smaller than that. Good luck and keep making pictures!

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I think you missed your profession as a microbiologist rufusbduck Smile This obsession with small things will ruin your eyesight!

ruffles
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You need to start hanging out with TGWNN:
http://www.candlepowerforums.com/vb/showthread.php?321289-500-Lumen-AAA-Flashlight-(photos)-Work-In-Progress/page50

(post #1483, a bit down the page)


 

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Here are the two bits I need to join, the chips soldered to the contact plate and what’s left of the brains.

After I stuck the two parts together with Fujik I needed to solder 3 spots on the brain board to the contact plate, the resistor, the capacitor, and the two pins of the IC that I had previously shorted together. Here is a crummy pic of the resistor connection.

Once all three had been soldered I filled the voids and buttered the edge with Fujik. Like a six year old with a very small layer cake.

Then I wrapped it in plastic and pushed it into my guage tube to cure.

We’ll see what it looks like later. I have to run off to the post office and won’t be able to play with this for a few days. I’m leaning toward a black solitaire with some brass like this one

What do you think?

Three Tanna leaves to give him life, nine to give him movement. But what if he eats the whole bag?

Scott

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Really impressive, a work of art!! I like the look of the brass collar.

I did a couple of soli mods with smt components…never again, just too fiddly for my sausage-like fingers Smile

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Here it is unwrapped.

And again with an 18650, a solitaire host, how it started (left), an lr44 button cell (right), and the reworked driver (center).

The more observant among you may have noticed only 2 chips where I stated in th op I would be using 3. Space condiderations aside I felt it would be a sort of flashlight hubris to run a solitaire at one full amp. It would work but in this instance my conservative side would not be denied so 700mA it is.

Three Tanna leaves to give him life, nine to give him movement. But what if he eats the whole bag?

Scott

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Plans changed so I got to stay home and play. I dug out my stash of brass tubing and cut up and soldered some things together.

The shorter one on the left is for Mum’s pinky and the longer one along with the stepped piece is for this mod. Why longer? Why the extra piece? Because I cut the head of the solitaire in two of course!

Well, “What for?” you might ask. So I can make it long enough to focus a zoomie, that’s why.

Tomorrow they will go out to my high tech lathe set up(not) and have some fins cut. Stay tuned. Shocked

Three Tanna leaves to give him life, nine to give him movement. But what if he eats the whole bag?

Scott

MRsDNF
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I'm running out of things to say rufusbduck. The driver there aganst the ruler must just be over 3/8 of an inch. Thats so tiny. Dumb question. You still have modes?

 

djozz quotes, "it came with chinese lettering that is chinese to me".

                      "My man mousehole needs one too"

old4570 said "I'm not an expert , so don't suffer from any such technical restrictions".

Old-Lumens. Highly admired and cherished member of Budget Light Forum. 11.5.2011 - 20.12.16. RIP.

 

Rufusbduck
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That was the idea. 3 modes, last mode memory, low voltage warning. I could probably do this with a Dr J Lux drive if I had one. Wouldn’t that be special.

Three Tanna leaves to give him life, nine to give him movement. But what if he eats the whole bag?

Scott

Rufusbduck
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Why is there a fast tech ad overwriting your avatar?

Three Tanna leaves to give him life, nine to give him movement. But what if he eats the whole bag?

Scott

MRsDNF
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If your talking about my avatar I see a mongrel looking Moose. I had to ask about the modes as I thought that this was the idea of the mods. How many more of the current chips would you be game to put on these drivers?

 

djozz quotes, "it came with chinese lettering that is chinese to me".

                      "My man mousehole needs one too"

old4570 said "I'm not an expert , so don't suffer from any such technical restrictions".

Old-Lumens. Highly admired and cherished member of Budget Light Forum. 11.5.2011 - 20.12.16. RIP.

 

Rufusbduck
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Functionally, it’s no different from before so the drive current depends on the ability of the host to radiate heat and the physical space available. For example a AAA Minimag has a larger head for more fins and a longer tube for more chips. There may be enough room in a solitaire for 3 where I currently put them but without lengthening the battery tube or using a smaller battery, that’s the limit. 1A would likely heat up fast and since there is not enough space for a decent sink might not be good for the led.

Three Tanna leaves to give him life, nine to give him movement. But what if he eats the whole bag?

Scott

Rufusbduck
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I made a few more parts for the light.

Actually, it’s just the zoomie bits I wanted to show. The led fits inside the tube with the copper bottom which slides up and down in the other piece which is the extension for the head. It is long enough so that with the head screwed down, the lens pushed down on the end breaking the circuit(as with the original).

Still more to come.

Three Tanna leaves to give him life, nine to give him movement. But what if he eats the whole bag?

Scott

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Tested the driver with an xre I had lying around. Surprise, it works!
And since when “on” the pill will float I decided to try my hand at a DIY sink pad. I changed things around by desoldering the tube, reflowing the emitter(XP-G2 R5 3D) onto this new base and gluing the tube to that with AS-5 and filing off the excess plate.
I left a tag end if the awg 14 protruding to help anchor this part to the driver half. I’m getting a lot of reflection from the AS around the inside, it’s a bit tidier than this looks.
That’s all for a few days. I’ll need to make the brass fins before I do any more.

Btw, I used the fine tip on the wand with the heat turned up(400C) to solder the awg 26 Teflon wires to the pads. That tube is ~9 mm ID X 12 mm long. I filed a 10 mm round star down both in Dia and thickness to fit.

Three Tanna leaves to give him life, nine to give him movement. But what if he eats the whole bag?

Scott

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Next time I’m going to move the cap closer to the IC or directly between it’s last contact point and the ground plate.

Three Tanna leaves to give him life, nine to give him movement. But what if he eats the whole bag?

Scott

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I got to stay home one more night and made these.

The bolt is how I chuck the brass sleeve into the drill press. A hack saw blade screwed to a 1×4 block w/2mm of the teeth hanging over the edge and another block to raise it above the nuts. 1/2 crank per fin on the small ones and progressively more for the zoomie sleeve. Here’s how they look installed.

And

I think mum will be pleased and the delivery notice for the batteries came in the mail today so it and the Blues Bros will be shipping out soon. Everything works on the zoomie, modes etc and the beam comes to a fairly good focus(square die but with rings and artifacts). I turned the lens around and this smooths the beam out and virtually eliminates the rings. However, it is not quite as floody when all the way in. More like a spot to medium range. I have several of these lenses and I have one set up on the end of my “lathe” bolt with a sleeve to center it and I’m going to try and change the sphere radius and see what that does. The bezel is not glued on to the head yet and once it is there’s no changing this lens so I’d like to experiment while I can. Since this will change the focal length it will likely change the image at both ends but I need the data anyway.

I’ll post beam shots when I can show a comparison of the modded vs unmodded lenses.

Here it is again after about an hour and a half of spinning it on a file, various grades of w/d sandpaper, and turtle wax lens clarifying compound(brass sure polished up well!). I tried to match the former image angle to show the difference.

I’m not at home to check it out until Sunday evening.

Three Tanna leaves to give him life, nine to give him movement. But what if he eats the whole bag?

Scott

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Wow, you made it a zoomie as well? Thank you for the detailed pictures!

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Must be nice to have such talent! It was all I could do to get a double board driver in the HD2010 and working, lol

Nice work!

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The lights that he mods are so small

And the tiniest bits he'll install

Inspiration has struck

Our dear Rufusbduck

Whose creations will always enthral

Smile

 

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Chloe, as long as I’m “prototyping” I figure I might as well try a few different ideas in one light rather than mess up multiple hosts. This used one I picked up on the cheap with another light on Fleabay so it made an ideal host for some new ideas. The driver works great and the zoomie mechanism works as well but the lens needs to be tuned to the length of the threads to get much change in the beam.

Thanks DBCstm. If by talent you mean a willingness to screw up and try again then I’m your man. I have a ziploc bag full of toasted 7135’s and more than one or two LEDs from learning to reflow. Some skills elude me still. I can’t say it often enough, I would be lost without my magnifying lamp.

Three Tanna leaves to give him life, nine to give him movement. But what if he eats the whole bag?

Scott

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Is that anything like the D Mag aspheric lens I’ve got laying on my nightstand? Smile

Yeah, we’d make quite a team creating Bar-B-Que electronics for the avid DIY’er. I’m learning though. You guys make me take leaps which of course creates more Bar-B-Que which then leads me to take more leaps…it’s an addictive sport for sure! lol

The difference is, you manage to pull it off and make it look good! Wink

Edit: RufusBDuck, I hereby officially offer up my photography skills to better display your glorious work! Smile Wink

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