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