I completed this light, was good except reflectors ended up a little short of lens and I did not like the spacers I used. So time for a rebuild.
Specs - Triple XML2 LEDs on 21mm Noctigon stars, screw mounted to homemade copper and al heatsink.
H6Flex Driver, Host will be FiveMega Elephant with 3 inch head.
(Elephant uses 4 x 18650)
Sink with 2 copper plates, Britelumens P7 Sink, Download Multi Sink
Sink next to FM 3 inch Head
Complete light, with PC rubber spacers. They had to go.
Added some height to heatsink with 3rd 3mm copper plate.
I don’t own a lathe, hand tools and drill press used for all these parts.
XML2 T6 3C LEDs.
LEDs mounted with 3mm stainless screws.
Spacers and screws building and assembly aids, might as well leave them there.
Light worked well, using Samsung INR 20R 18650s direct drive I measured 5.6Amps on fresh cells.
Light gets hot obviously, but I think heatsink combined with large mass of head and body was doing it’s job.
Rebuild has more mass in heatsink, better contact with head, much better contact with body.
Will require some rubber mallet work to get heatsink all the way into the host tube.
Make sure I now have height correct
Looking good,reflectors just starting to contact lens. Should be able to squash the o-ring a bit and completely tighten bezel.
Why only two reflectors? That’s all I have!
Looks fantastic!!
Jesus that dude sold a LOT of those Elephants on CPF. Expensive, but very sleek looking build.
The heatsink is awesome.
Yeah Elephants are not cheap, solid chunks of metal though.
Final (I think) prep of top surface:
Really sharp looking job done there. Amazing work!
Looks like you're another candidate for the 2014 BLF DIY Contest.
Amazing. Orsm light you have created there. The workmanship and skill you have shown is exceptional. Is there another reflector coming?
Thankyou. I’ve come across some of your mods, some good stuff!
Thankyou. I made a booboo with reflector order, missed an email asking if I wanted part order or to wait for full stock.
So I either have 7 nearly here, or 10 here soon, I hope…
Enough for another couple of lights. This will keep you out of trouble for awhile. 
Still waiting on reflectors. No problem, this is a slow build.
Made a sink for the H6Flex driver. Mates to inside rear of main sink.
Mounted the LEDs.
Jig for mounting the driver. Decided to follow the designers advice and use the thermal tape.
Have to be accurate to line up grooves for wires that will go forward to LEDs, couple of bamboo skewer tips doing that job.
Rubber piece to spread load while clamping. Now wait 24 hours.
Awesome work with nice photos to show it!
What reflectors are those? Kind of reminds me of ones I’ve seen in the past that were used on XR-E LEDs…
They are Cree XML-10R. (10 being 10 degrees)
Nice…guess I’ve fallen behind the times, but nice to know there are more options for reflectors available these days!
Progress:
Momentary modded Mag switch
H6Flex on sink. Very “un-Chinese” driver - plenty of room for 18 AWG wires.
Complete engine
Arctic 5 thermal greased
No point scratching up host doing the switch connection
Brass connector on rear of Mag switch slightly too long. So tailcap won’t quite make it home.
Will need to remove switch and shorten a tad. Piece of wire allows me to test light.
Test success.
This morning I went to PO and picked up reflector parcel.
I was hoping they would not package like this:
I used 10 cents worth of plastic bags…
When I received reflectors from Cutter like this, there was a cloudy mark left from having reflectors packed inside each other.
These reflectors don’t have that mark but I’m sure all the imperfections I do see are from packaging.
FWIW when I ordered reflectors from Mouser recently they showed up packaged VERY nicely. They were not nested - they were held apart by a thin plastic thing and sandwiched between two pieces of cardboard, then shrink wrapped. Very secure + clean. The entire order was packaged super nicely and professionally.
I’m not sure how practical ordering things from Mouser is for you.
Good work!
That’s exactly how I would package - sandwich with some scrap cardboard, fairly simple…
I just checked mouser - they don’t have the XML-10R reflector. It’s not stocked many places.
Very disappointed that build has stalled due to H6Flex problems.
Light works, have it in UIF/UIF mode.
Problem is, if I turn on to lowest setting it will run for 30 minutes (as long as I have tested).
If I select any level higher than lowest, it runs for a few seconds and turns off.
Logically, if it can run on low (1 of 8 levels) for 30 minutes or more it should last a few minutes on level 2 (if it was shutting down due to heat)
(Using momentary button held down I can select high mode and run for several minutes…)
I’ve read manual, a lot!.. if it was low voltage it would give warnings, also it waits 1 minute when low volt setting reached.
Further problem, I just can’t follow programming sequence. I’m obviously getting into menu but just not getting response expected as per manual.
Any advice welcome! I was going to wait to early new year before emailing taskled, really don’t want to pull this driver out….