R86s - Build From Scratch- It's a coke light, but it ain't diet

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RaceR86
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R86s - Build From Scratch- It's a coke light, but it ain't diet

Update 09.06.2013

When this contest was announced, it took me about a day to go shopping. The grocery store is just full of flashlight hosts.. Big Smile
I picked up three. Just in case I mess one or two up…

I have to admit, I started “working” on emptying the light the same day… 0:)
I also cut out the bottom out of it, just to see how flimsy the box was, and If I really wanted to work on it. I think it is doable. So I have decided that it will be my host.
Since then, I have waited for the contest to begin. It think I will be able to build a light out of it. Triple XM-L reflector should fit perfectly.. The hardest part will probably be to make a sort of battery door or something. I don’t know how that will be done. There are many things Im not sure how I will do. But I plan on using Ni-MH batteries.
Wish me luck… Smile

Update 10.06.2013 – Build has started
Isolation to the body while working on it.. Bottom and top was cut out with Dremel.

OP triple reflector from DX was grinded down a bit on the edges (with a not appropriate grinding stone tool). Stock SRK reflector would fit nicely btw..

This is probably as good as it will ever look.. Smile

I bought a 3mm drill for glass and stone tiles. I did not have much faith, but gave it a try earlier today.. Gently and slowly..

Drill press is not legal, not sure if it would be good to use on the glass anyway, might be too easy to add much force… I used the Dremel. But it wast the best place I had to secure the lens when I was working on it..

Ehm.. yeah.. This happened on the first hole, and the second got worse… Ill just use a plastic lens (from Maglite), that way I will be sure that it will not break/shatter after the light is finished.. While on the subject, does anyone have good tips for drilling through glass lenses??

A possible driver circuit arrived in the county today…. Smile Should have it in around 2 days..

Update 14.07.2013
I made a thread about the Asgard driver circuit. Lots of time went to that, but I had issues after some mod attempts. I got a bit fed up with it, and it took a away a lot of time for this build.. Ill get back to it some time in the future…

A few work shots:
Various rods salvaged from printers and such come in handy..

So does a huge plate of copper and a little “hand-tool” for easy cutting.. I finished it off with a dremel..

Some durable plastic, fairly thick.

The start of 6AA battery carrier? Yupp! .. The springs I had available were a bit short (I plan on replacing them once a receive a 100-pack of some longer ones)

Plastic lens from a new Maglite. The screws holds it in place and avoids the lens from getting scratched up if standing on the head.

Kapton tape on the back, just in case…

I used some XM-L T5 5C that had been used in various lights. A corner on each sinkpad were cut in order to easily make room for the screw holding the reflector.

Coke light… Smile

This should give you a better picture of the content inside the light…

Hidden side switch, only the owner know where to push… Smile …or just try your luck in the area of the light that does looks a bit beat up.. Silly

Switch position can be adjusted back and forth. If necesarry, I could make a new switch board with electronic switch.. The “pill” have room for very wide driver circuits and with heights up towards 17mm. You can also see the screw hole for the reflector screw..

Everything sits nicely in place. Normally I use high quality thermal paste under the emitters, but fujick was used here. It was just more convenient while working on things.. Its not like its 3+ amps to each emitter.

Did some more work to the switch…

Wired…, notice my “wires” between the positive emitter connection. Works nicely for making a flat and low surface…

I made a thingy to hold the wires in place.. (look beside the button)
For now I opted for a highly sophisticated driver circuit. Almost on level with the Asgard… Silly
Some air, some love, some wires, more air.. and… more air.. Smile I never had a such sophisticated driver before and was curious how much current I would get…

Fresh from the charger, 3 Eneloop XX managed to squeeze out over 6 amps, this went quickly down towards 5A… On 2nd start up it was more like 5A start and 4,5 after 30 seconds, still falling, but not that fast. Im guessing that 3 batteries would do 4A+ for some time. I used 22 AWG wires..

6 batteries! J) 7,3A at startup… These were holding the current quite stable at around 7A after 30 sec.. It was falling very slowly.
My guess is, I would see 6+ amps for a long amount of time…

Compared to a sibling.. Smile

King Oscar came to the rescue with some reinforcements… (the box said King Oscar).. Made a hole for the invisible side switch. It may look thin, but it seems to be 10x stronger than the flimsy coke box..

Now, how to finish the tail…

Ehm, I never did that part.. Oops

The plan was to cut some part of some hinges and use a genius plastic thingy that you just press and then in locks and unlocks… (bad explanation but, anyone know the name?? I might be interested in more of those..)
In order for those to fit, I would have to make the battery carrier a little thinner, which would have been easy. I could also make a lid out of plastic and spray paint it silver metallic… But until I have tested the Asgard a bit more, and improved some things (battery carrier, and side switch), Ill leave it as it is. Plan was to JB weld the the top of the pill (not the bottom half) directly to the body for better heat transfer, but until I have made everything properly, Ill just leave it be..

Notice the ring at the bottom. Its from the “King Oscar” box.. Looks quite nice, and makes it durable.. Smile

Compared to a SRK..
You may see the area of the “hidden switch”.. Silly Its that beat up area.. Its working, but not super smooth. If using a mechanical switch I would prefer to make a hole in the Coke box, if doing that, I would replace the box with a new and better looking one…

This build might be properly finished some day, until that day…

Coke light, but not diet… Wink

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Edited by: RaceR86 on 07/14/2013 - 14:03
Rufusbduck
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Good luck Davie

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

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I am not an expert,

but shouldn’t you have obviously chosen a Pepsi host instead? Just sayin’.

The lighter the brighter the better.

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Coca~Cola Rules!!!

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texaspyro
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Old-Lumens wrote:

Coca~Cola Rules!!!

Mexican Coca-Cola rules! American stuff is chemo-crapo…

Bort
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texaspyro wrote:
Old-Lumens wrote:

Coca~Cola Rules!!!

Mexican Coca-Cola rules! American stuff is chemo-crapo…


ditto

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raccoon city
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Original formula Coca-Cola for the win!

RaceR86
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I have never tasted Mexican Coca-Cola…
I am probably guilty in consuming somewhere between 0,5-2l Coke on a weekly basis. 0:)
Most people know I always take Coke over close to anything else..
I never buy those small can boxes though. They cost 13,20 NOK a piece. 2,29 USD$

Considering how much Coke I drink, it was a fairly easy choice for me. This light might also be a gift to a buddy of mine. So the plan is to make it a bit personal, and hopefully have other features that he will like.. Smile
I have many ideas.. But I don’t have the driver circuit that I might put into the light yet.. Until that part is figured out, its a bit limited how much I can do… Not sure if it will be electronic or mechanic switch yet, or the size of the driver circuit. Those things are quite crucial when working within limited space.

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dave_
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Great host choice!
Are these cans strong like ‘in the old days’?
After can deposit was introduced, cans disappeared here almost completely. They came back a few years ago, but in more long-ish form with really thin walls. Can’t build anything out of that. ^^
Good luck with your build! Smile

RaceR86
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Thanks! Smile
Ehm.. the walls are very thin and flimsy… Silly
Im feeling quite sure its the same walls as the ones you have in Germany. The box is made somewhere in EU. It does not take much force to crush it with a hand..
When I measured the top diameter and saw how nicely a 50mm triple reflector should fit, it was just meant to be. Despite the thin walls. I will have to make it fairly “crush proof”.

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texaspyro
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RaceR86 wrote:
I have never tasted Mexican Coca-Cola…

It’s made with real sugar, not that high-fructose chemical cocktail.

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Love your choice of the real thing! Wink

Our friend runs a Mexican Food Restaurant and has large bottles of Mexican Coke, we always drink that when there, and go there all too often. My wife drinks Coke or water. No coffee, no tea, almost nothing else at all. So we go through a couple or 3 cases a month pretty easily.

Can’t wait to see how you pull this one off!

Edit: I have a very old Coke can made of tin, with the pull tab still intact. No aluminum save for the top with the old style tab that’ll cut ya. Smile

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texaspyro wrote:
RaceR86 wrote:
I have never tasted Mexican Coca-Cola...
It's made with real sugar, not that high-fructose chemical cocktail.

European made Coca-Cola's have real sugar, not that horrible HFCS.

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Thanks RaceR86 for the idea. Instead of Coke cans I decided on VB cans. Unfortunately I may have to stop using this idea as my head hurts to much in the morning. Looking forward to whatever you create and dont forget to add Scotch. Tastes better than Mexican Coke then. Wink

 

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A Coke can is a great idea. This was my first impression as I see the Skyray King the first time. A can with three LEDs.
I prefer Coke instead of Pepsi. Maybe I would chose a special edition Coke can if it is available in Norway at the moment. A special flashlight in a special host.

Light up the darkness.

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Canadian soft drinks still use real sugar, mostly. Definitely a different taste to the HFCS variety; not a fan.

Welcome the night.

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I made a bike light from a metal shampoo bottle once, way back in the halogen days. I used it every week for 6 or 7 years and it’s still around somewhere. Can’t remember the name of the brand, had some guy with long hair frowning on it.

Looking forward to the build report!

ps. I only drink coke with rum, tastes much better Smile

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I wonder why every light is build in tubular form…why not using a fishermans friend bonbon metal box….? Would be easy and nice.

RaceR86
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Werner wrote:
I wonder why every light is build in tubular form…why not using a fishermans friend bonbon metal box….? Would be easy and nice.

There is your Idea. You should join in on the fun Werner! So, when do we see the fishermans friend bonbon metal box light build? ^^

Actually, I was thinking about using a sardine box (flat square box). But I have done a “box” light, and that one will probably not be my last.
For this project, I wanted more space in order to make a bright NiMH light..

Im a bit surprised no one of the other builders have started a beer light build… Beer

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First post updated. Several build pictures…
Its a coke light! Smile
Love

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i was actually considering a aluminum budwieser bottle build... but thought it was too close to what you were doing.  i was also considering cannibalizing my floor lamp for a build. the upright tube looks about the right size to fit a 26650 and it has a HUGE head on it (metal shade) lol

 

that thing looks awesome! good work

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I don't know anything about drilling holes in glass, but I think I have seen oil used to help keep from shattering the glass. I can't swear to that, but here's a Wiki how to on it.

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M3TAL_L0RD wrote:

texaspyro wrote:
RaceR86 wrote:
I have never tasted Mexican Coca-Cola...
It's made with real sugar, not that high-fructose chemical cocktail.

European made Coca-Cola's have real sugar, not that horrible HFCS.

They use whatever is available locally. Corn syrup made from maize in the US, sugar made from sugar cane in Mexico and sugar made from sugar beet in the EU. Dont know about Canada (maple syrup? :D), Russia or Asia (Stevia maybe).

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If you put some crappy driver inside you can call it Coca-Colla Diet Big Smile

 

ruffles
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Nice build! I wonder if you could paint a few layers of epoxy on the inside to give it a little more structure.


 

RaceR86
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Sirius9 wrote:
If you put some crappy driver inside you can call it Coca-Colla Diet Big Smile

Moi, putting a crappy driver in a light? Im insulted.. Silly

I have the following options available. 2 different 5A drivers from lck-led, Qlite with extra 7135s, the original SRK driver, Dr Jones Lumodrv with a bunch of extra 7135s as options.. Probably a few more inferior drivers..
Compared to all the above, Im thinking on some more sophisticated stuff :hat:
…maybe… Otherwise, I will pick one of the above..

ruffles wrote:
Nice build! I wonder if you could paint a few layers of epoxy on the inside to give it a little more structure.

Thanks! Smile
Epoxy would probably work. I plan on use some metal instead… Should be better for heatsinking..

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Old-Lumens wrote:

I don’t know anything about drilling holes in glass, but I think I have seen oil used to help keep from shattering the glass. I can’t swear to that, but here’s a Wiki how to on it.

Thanks..
Helpful, but my attempt was too optimistic. Not a surprise.
I considered to try drilling from both sides (like recommended in the link), because the glass got the crack when I went through.
But it will not be a good solution to drill that close to the edge of a glass lens anyway. Like the link said:
…“never drilling within 3/4 inch from any edges.

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RaceR86 wrote:
Its a coke light! Smile Love

It looks great, but it's not light. This is coke light: Tongue Out

=the=

 

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Bugger!
I though I was making the first one..
Coca Cola beat me too it. Silly

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texaspyro
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ruffles wrote:
Nice build! I wonder if you could paint a few layers of epoxy on the inside to give it a little more structure.

Two layers of 6 oz carbon fiber cloth will make the thing indestructible/uncrushable…

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Tips for drilling glass

 

Clean meticulously. 

Spray/drip with rubbing alcohol while drilling so it is always wet. 

Go slow. Very slow. Clean often.

 

Hope that helps if you feel like trying something similar.

~ Ledsmoke ~

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