EDC/Convoy S3 headlamp (MOD)

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eebowler
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EDC/Convoy S3 headlamp (MOD)

As per usual with my mods, it’s not very neat but, functional and probably the best headlamp I have! Big Smile With the right tools, it’ll look a lot prettier in the end. The idea was simple: USE THE BODY AS THE HEATSINK.

 photo IMG00239-20131024-1205_zps273d97ca.jpg  photo IMG00240-20131024-1205_zpsd49aa2c8.jpg  photo IMG00241-20131024-1205_zpsdfcdd67e.jpg

What I did was pretty simple but hard to impliment given available tools. Sad

  • Cut off the head so about 1/2 to 3/4 the heatsink sticks out when it’s screwed into the body. (to ensure you have enough head to shape to fit snugly onto the body.)
  • Remove anodizing (optional) from the flat spot on the body, cut a 4C, XML2, 16mm noctigon to size and epoxy it to the flat spot.
  • File, grind, cut, saw, sand, dremel and do what ever it takes for the head to fit snugly onto the body and over the LED to produce the beam pattern you want.
  • Epoxy the reflector and window into the head. (there is no compression from the pill to press the window onto the ‘O’ ring to make a proper seal.)

The driver (8X 7135 Dr Jones Lucidrv) is put into the pill like normal but the output wires are extended to reach the LED on the body.

  • insert driver into pill, screw pill into body, epoxy in place and solder output wires to LED.
  • TEST.
  • Epoxy head to body ensuring that there are no entry points for water to get to the LED/reflector assembly. Ensure also that epoxy does not get on the LED!
  • Epoxy closed the holes in the pill that the output wires pass through and epoxy the wires down to the body.

At the moment, I’m using a nitecore headband for the light which i’ve zip tied to the headband since in my opinion, the wide bands of the nitecore would reduce heat dissipation. In future, I’ll be ordering a headband from FT with silicon rings similar to what SPARK (my inspiration) uses.

PROBLEMS: I had major issues shaping the head. Besides lack of proper tools, (part of my shaping process involved cutting vertically into the head with a hacksaw and breaking off bits with a leatherman,) I ended up getting dremel dust inside the reflector and while washing it out, scratched the surface a bit Sad

If you use slow setting epoxy (cures with less defects and gets into seams better), epoxying the head down to the body is a real pain in the ass since you have to hold it in the ideal position for a WHILE.

In the end, i am totally satisfied with the final product. I have a well heatsinked, ~700 lumen headlight with multiple modes and a low output of maybe 3 lumens that is submirscible to some degree in case I have to swim during an outing. It also functions as a helmet light (worn underneath the helmet) but, in my opinion, has a too wide beam pattern to be of much use when going fast on wheels. What’s ideal for one situation is not ideal for the other i guess. shrug.

Thanks for looking Smile

My gratitude to those who are willing and able to help others (in whatever way you can)! Being human is more than just existing for yourself. Smile

Edited by: eebowler on 11/16/2013 - 10:28
jacktheclipper
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Interesting .

Thanks for sharing .

eebowler
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Hahahah. I guess people don’t care.. Beer

My gratitude to those who are willing and able to help others (in whatever way you can)! Being human is more than just existing for yourself. Smile

zelee
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nice idea Smile
if only someone who has a connection with a light manufacture produce this kind of light :~

Don’t mistake my kindness for weakness.
I am kind to everyone, but when someone is unkind to me, weak is not what you are going to remember about me.

djozz
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nice! (sorry, I miss a lot of threads nowadays, too many nice threads moving too fast down the list to keep track).

It looks like a good working flashlight, and I love the idea to just chop off the head to make a head lamp. Hmm, would it be possible to do this a bit neater?...

Thanks for making me think Smile

RMM
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Very cool!

Mountain Electronics : batteries, Noctigon, and much more! What's new? 

Ledsmoke
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This is so similar to something I've been wanting to do with a 18350 cell for a loong time. 

Great minds think alike. (Or something)

Thank you for sharing. It reminds me that I should get off my butt and start finishing some projects.

(Which means I'll only sleep 1 hour on the sofa. Ha haa!

~ Ledsmoke ~

Dutch humor:

[quote=djozz]

 I do not think that the BLF-community ben

CheapThrills
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I still cannot understand, why there are almost zero budget options on this headlamp format WITHOUT an aspherical lens…

unknown00101
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CheapThrills wrote:
I still cannot understand, why there are almost zero budget options on this headlamp format WITHOUT an aspherical lens…

Even the cheapo plastic ones are 20+. Flat Stare

It doesn’t make sense to me either. I just settled for the Home Depot 3 AAA plastic 2 pack for $10 or $15. It functions somewhere between an Incan and a decent led.

MRsDNF
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Very novel and creative. Nice mod.

My current and or voltage measurements are only relevent to anything that I measure.

Budget light hobby proudly sponsored by my Mastercard and unknowingly paid for by a hard working wife. 

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

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.

 

Tech2
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This would be a great manufacturer option. Nice work.

eebowler
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Thanks guys Smile ( although it feels like you’re buttering me up now Silly )

CheapThrills: Yes, It aggravates me how, well made, handheld 18650 lights are cheap and easily available while there are no equals in the headlamp world. I don’t like zoomies and will not buy any for the sake of experimentation.

This idea of this light was born about a year ago when I recommended a NW, Spark ST6 headlamp for a friend. It costs A LOT MORE than I could afford but it’s functional and bright. As a modder, I thought, ‘yeah, I can do that’ and probably make it brighter too!

For a LONG time I thought of modifying a zoomie but information about reflector size was not clear and heatsinking in the light I thought was most moddable was poor. For almost as long, I thought of messaging OL and asking him to make a right angle adapter to screw onto the body/head of a Roche F12 for example but, besides -$$$, making proper +ve connection might have made the whole process too complicated.

The actual host made itself available when the driver in the EDC failed and I was just too upset to repair it Silly so decided that I’ll either destroy it or make a gem by attempting this mod. Smile I’d recommend to anyone who wants to try this build to get either the spark headband or a cheapie from FT or wherever. Another issue discovered is that the round barrel of the body pressing on my forhead is not the most comfortable feeling Silly so the silicon backing of a proper headband would be nice. Smile

My gratitude to those who are willing and able to help others (in whatever way you can)! Being human is more than just existing for yourself. Smile

Speedsix
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I just saw this thread. I totally agree about the frustration of lack of decent low-mid priced 18650 headlamps. I never understood why we can buy a dozen different really nice 18650 flashlights in the $20-$30 range but there are very few 18650 headlamps in that price range and fewer that are any good.

Truth be told, I have not been happy with any of my 18650 headlamps. I had a Sparks, UF-H3 and a couple of others. The H3 was decent but stopped being reliable due to the contact pad wearing out. The Spark overheated and shutdown.

I have 15-20 trouble free 18650 handhelds but can’t seem to find a single headlamp worth buying.