A little mod to a Trustfire TR-J10 - Finished. Beam shots in Post #1

27 posts / 0 new
Last post
Old-Lumens
Old-Lumens's picture
Offline
Last seen: 3 years 3 months ago
Joined: 11/04/2011 - 11:39
Posts: 7478
Location: Tyler, TX, USA
A little mod to a Trustfire TR-J10 - Finished. Beam shots in Post #1

I got this light in the mail today,

j101a

j101b

the SST-90  that I got from ebay for $14.50. I was worried if it would be ok for that price and I was right! It has some dings and nicks and it DOES NOT WORK!Yell  Oh well, you win some, you loose some. BUT... if the led is ok, it's still cheaper than buying a SST-90 led. So, I didn't feel too bad and as I looked it over, it seemed it was all about ground, or lack of it.

Well, you know me, I went ahead and tore it down to mod it. Heck with it, I would do that even if it did work!Tongue Out

 

 

j101f

Here's the driver. It looks like it might be a genuine TF driver.

 

j101g

Here's the important side, the side where I will play with resistorsLaughing. It sure looks like someone already played with it. That R300 looks like it should not be there. A little small for the pad spacing, but possible it was done at the "factory"...Undecided

 

 

j101d

But, when I got to the led, look at this crud! What the heck is this? I guess it's supposed to be the same thing as thermal paste, but I can tell you, it was working as a fantastic isolator. It's way too thick to do anything at all, except let the led get hot fast. 

 

j101e

There was a copper star in it though, so that's almost a good thing, except it's not direct to copper, so it's not much better than aluminum.

Hey, where the heck is the led??

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

j101h

The SST-90 is now on a much better star. Yes you can reflow an SST-90 to an MT-G2 star. The center pad is just about perfect and the outside pads are close enough to work.

.

.

.

.

.

Now, why did they have that huge "thermal pad" in there? Here's why. 

j101i

There is a divot right in the center of the led shelf and it's raised all around it, so the star is not making any contact to the shelf. I guess they thought the pad would "take up the slack". WRONG!

 

I don't have a great fix. It needs to go to a lathe, but I did figure out something.

j101k

I cleaned off the high spot, drilled out the divot and pressed in a piece of copper. At least the star will sit down flat, once I smooth it all off.

.........................................

Let's talk about power. This light is designed for 2x26650 batteries. I thought it would put out at least 5 amps or so. WRONG!   I set up a test station with my meter in line between the driver and the led. Stock, the driver gave 3.2 amps on high. WTH? Well, I guess it's a safety thing. It won't heat up fast with low amps...  So, knowing absolutely nothing about figuring out resistors, (I know I have been told before how ot, but it just does not sink in any more... sadly), I decided to just jumper the ones there and see what I got with no resistance in the circuit.

Are you ready?  I am using two of those Sony US26650VT cells here, can you guess?

On high I read 15 amps!Surprised Oooops!Embarassed  Of course, it only lasted a few seconds and just as I was letting off of the negative terminal, the led went out. Undecided NOPE, it did not fry, the wire came off the terminal - the solder melted and the wire fell off.Laughing

OK, so I don't think that will work...  I removed the jumpers and started playing with the resistors I have, (which are few and all the wrong ones). I never got it where I wanted it. I got to about 7.75 amps, (I am shooting for 10 amps) or I got to 12 amps, but never where I wanted it. I finally got frustrated enough and confused enough, to just settle on 11.2 amps.  Yep, that's a little high... or is it? I can tell you that the led never turned blue, never failed, never flickered or looked off color. I think I will attribute that to the Copper star. I also think it's one of those lights that you don't want to leave on high for very long at all.Wink

So, I will try to finish the build by this week-end. I think I will probably use smaller wire from the driver to the led, to add a little resistance.

More when I get more done......................

-----------------------------------------------------------------------------------------------------------

It's done and here are the final shots.

t901a

One of the biggest issues was the reflector. It has such a huge flat spot on the bottom, that there's no way thick wires can go on the star, or the reflector will not seat far enough. It is one of the reasons I ended up using 22ga solid teflon wire. The other reason was to calm down that 11+ amps, which the light just cannot handle. There's no real meat in the head and it would just be a mistake.

 

t901b

I did drill and tap for two screws, but only so I could squeeze the livin heck out of the star, so there would be minimal AA compound in between. I took the screws out after, since they just stick up too far for that reflector.

 

t901c

The original problem with the light not working, was that the driver was not grounded. It was too tall in the driver pocket and was actually held off the step inside. I ruined the original brass hold down ring, to get it out, so I made two copper rings. One to go under the driver and one to go on top. That way the driver clears and is grounded well.

t901d

One ring below the driver,

t901e

One ring above the driver. I also used a heavier spring and a lot of copper braid, to take the heat of the amp draw.

 

t90done

All done and right now it reads 8.6 amps (tail cap reading), on high. That is much more reasonable than the 11+ amps it was doing. I believe the 22ga wire had a lot to do with cutting sown the amp draw. The tail cap spring has also been braided.

 

Beam shots in Post #1.

My PayPal address: oldlumens (insert the @ sign here) gmail.com

My YouTube Flashlight Video Channel

The BLF Modding Links Thread 

http://imageshack.com/a/img922/1374/jQ2wdL.jpg

 

Edited by: Old-Lumens on 02/14/2014 - 02:34
Old-Lumens
Old-Lumens's picture
Offline
Last seen: 3 years 3 months ago
Joined: 11/04/2011 - 11:39
Posts: 7478
Location: Tyler, TX, USA

90b1

90b2

90b3

90b4

90b5

My PayPal address: oldlumens (insert the @ sign here) gmail.com

My YouTube Flashlight Video Channel

The BLF Modding Links Thread 

http://imageshack.com/a/img922/1374/jQ2wdL.jpg

 

MRsDNF
MRsDNF's picture
Offline
Last seen: 19 hours 17 min ago
Joined: 12/22/2011 - 21:18
Posts: 13254
Location: A light beam away from the missus in the land of Aus.

Warning to all. This flashlight will not be safe to turn on high unless placed in liquid nitrogen for cooling.

 

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
Rufusbduck's picture
Offline
Last seen: 1 year 2 weeks ago
Joined: 04/04/2012 - 15:34
Posts: 10389
Location: Golden state

Better wear oven mitts too. >)

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

Scott

Ledsmoke
Ledsmoke's picture
Offline
Last seen: 11 months 3 weeks ago
Joined: 08/08/2011 - 16:05
Posts: 1995
Location: Denmark

Wow! That should put some light out there. 

I can not believe the price you got that light for though. Quite a coup. Looking forward to the glam shot already Smile

~ Ledsmoke ~

Dutch humor:

[quote=djozz]

 I do not think that the BLF-community ben

Gj
Gj's picture
Offline
Last seen: 4 days 2 hours ago
Joined: 06/26/2013 - 15:44
Posts: 3063
Location: NY,USA

Who says you can't turn a sow's ear into a silk purse?

18sixfifty
18sixfifty's picture
Offline
Last seen: 5 months 1 week ago
Joined: 12/25/2012 - 20:19
Posts: 4161

Nice, I see that light around quite a bit and would love to pick one up for that price. I didn’t know you could put an SST-90 on a MT-G2 board, thanks for that. I have a couple de-domed ones laying around. Now I might just get to playing with them.

Have you considered de-doming that emitter? It really does help throw a ton and they are super easy to do. Let it heat up and it will pull right off.

Looks like another very cool mod.

I’m a junky, I mod lights so I can sell lights so I can buy more light to mod so I can sell lights to buy more lights to mod.

ImA4Wheelr
Offline
Last seen: 1 week 5 days ago
Joined: 02/03/2013 - 14:51
Posts: 7927
Location: SC

Whoa, you turned a tame light into a monster.  very nice mods.

MRsDNF
MRsDNF's picture
Offline
Last seen: 19 hours 17 min ago
Joined: 12/22/2011 - 21:18
Posts: 13254
Location: A light beam away from the missus in the land of Aus.

ImA4Wheelr wrote:

Whoa, you turned a tame light into a monster.  very nice mods.


I’d perhaps suggest more a monster fire breathing dragon.

 

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.

 

blueb8llz
Offline
Last seen: 1 day 11 hours ago
Joined: 06/02/2012 - 01:16
Posts: 3022
Location: California

looking forward to the beamshots

Old-Lumens
Old-Lumens's picture
Offline
Last seen: 3 years 3 months ago
Joined: 11/04/2011 - 11:39
Posts: 7478
Location: Tyler, TX, USA

Finished, last shots in the OP and beam shots in post #1.

My PayPal address: oldlumens (insert the @ sign here) gmail.com

My YouTube Flashlight Video Channel

The BLF Modding Links Thread 

http://imageshack.com/a/img922/1374/jQ2wdL.jpg

 

Old-Lumens
Old-Lumens's picture
Offline
Last seen: 3 years 3 months ago
Joined: 11/04/2011 - 11:39
Posts: 7478
Location: Tyler, TX, USA

18sixfifty wrote:
Nice, I see that light around quite a bit and would love to pick one up for that price. I didn't know you could put an SST-90 on a MT-G2 board, thanks for that. I have a couple de-domed ones laying around. Now I might just get to playing with them. Have you considered de-doming that emitter? It really does help throw a ton and they are super easy to do. Let it heat up and it will pull right off. Looks like another very cool mod.
I'm sort of opposed to de-doming anything any more. Only because I have ruined every one I have tried.Frown  I will leave it to better modders.

My PayPal address: oldlumens (insert the @ sign here) gmail.com

My YouTube Flashlight Video Channel

The BLF Modding Links Thread 

http://imageshack.com/a/img922/1374/jQ2wdL.jpg

 

saypat
saypat's picture
Offline
Last seen: 16 hours 32 min ago
Joined: 07/13/2011 - 20:32
Posts: 3576
Location: Calif

.

MountainKing
Offline
Last seen: 3 months 2 weeks ago
Joined: 12/01/2011 - 03:20
Posts: 2273
Location: Lost Islands ™

Great thread man. Read every bit of it and enjoyed it!

Never ever forget and forgive. Niwal**er new kid on the block trying to act tough.
http://budgetlightforum.com/node/24847
Do not support this brand.

DINODIRECTSCAM COMPANY. DO NOT BUY
http://budgetlightforum.com/node/11324?page=2#comment-254983

Ledsmoke
Ledsmoke's picture
Offline
Last seen: 11 months 3 weeks ago
Joined: 08/08/2011 - 16:05
Posts: 1995
Location: Denmark

I must say that after you went li-ion your mods are becoming quite insane. I love it Big Smile

Great work O-L.

~ Ledsmoke ~

Dutch humor:

[quote=djozz]

 I do not think that the BLF-community ben

photon1k
photon1k's picture
Offline
Last seen: 3 years 3 days ago
Joined: 02/11/2011 - 23:29
Posts: 901
Location: Lotus Land, Canada

Nice. Tail current of 8.6A x 4V x 2 cells = 68 watts – small wonder it gets warm. 8)
What kind of run time do you get on high?

xmint
xmint's picture
Offline
Last seen: 5 years 5 months ago
Joined: 02/28/2013 - 21:57
Posts: 389
Location: Surrey, UK
Old-Lumens wrote:

18sixfifty wrote:
Nice, I see that light around quite a bit and would love to pick one up for that price. I didn’t know you could put an SST-90 on a MT-G2 board, thanks for that. I have a couple de-domed ones laying around. Now I might just get to playing with them. Have you considered de-doming that emitter? It really does help throw a ton and they are super easy to do. Let it heat up and it will pull right off. Looks like another very cool mod.
I’m sort of opposed to de-doming anything any more. Only because I have ruined every one I have tried.Frown  I will leave it to better modders.

I know the feeling Sad I’m 0 for 4 trying to de-dome MT-G2s. Mind you if the 90s are easy might have a go with one

The views in this post are mine, they are views and beliefs only, and not to be taken as facts.

Chazzy
Chazzy's picture
Offline
Last seen: 3 months 2 days ago
Joined: 06/23/2013 - 13:24
Posts: 295
Location: California

Sunglasses are required! 8)

Awesome mod OL!

"Whoa that's a bright light!" ... Yea I guess.

Old-Lumens
Old-Lumens's picture
Offline
Last seen: 3 years 3 months ago
Joined: 11/04/2011 - 11:39
Posts: 7478
Location: Tyler, TX, USA

photon1k wrote:
Nice. Tail current of 8.6A x 4V x 2 cells = 68 watts - small wonder it gets warm. 8) What kind of run time do you get on high?
About 2 minutes before it gets so hot you can't hold it.Wink Don't know the run time on high, since I feel it gets so hot, it needs to be lowered.

My PayPal address: oldlumens (insert the @ sign here) gmail.com

My YouTube Flashlight Video Channel

The BLF Modding Links Thread 

http://imageshack.com/a/img922/1374/jQ2wdL.jpg

 

Gj
Gj's picture
Offline
Last seen: 4 days 2 hours ago
Joined: 06/26/2013 - 15:44
Posts: 3063
Location: NY,USA

Nice! Cool

djozz
djozz's picture
Offline
Last seen: 39 min 18 sec ago
Joined: 09/07/2012 - 17:04
Posts: 16678
Location: Amsterdam

Missed this one until now. Thanks for sharing this mod OL, the SST-90 on copper was not done yet, and in a great performing light, nice!

rollinstone157
Offline
Last seen: 2 years 7 months ago
Joined: 12/31/2013 - 13:08
Posts: 300
Location: NJ-PA Area

I just got a pretty good deal on one ($41), so I’m gonna try and mess with it a little and I’ll report back on how it goes!

gitira6
gitira6's picture
Offline
Last seen: 1 year 2 months ago
Joined: 12/16/2013 - 18:41
Posts: 60
Location: northeast pa.
Old-Lumens wrote:

photon1k wrote:
Nice. Tail current of 8.6A x 4V x 2 cells = 68 watts – small wonder it gets warm. 8) What kind of run time do you get on high?
About 2 minutes before it gets so hot you can’t hold it.Wink Don’t know the run time on high, since I feel it gets so hot, it needs to be lowered.

I don’t find it too bad, the head gets really hot on high for a few minutes but the handle is not too bad. I run it mostly on medium and find that sufficient anyway, with high as a turbo mode. I love the big hotspot, and it throws like hell. Wonder how many lumens its putting out. I’m getting over 8 amps on 2 kk’s. It’s a beast. Glad I bought it. Thanks O-L.

dperreno
Offline
Last seen: 6 months 3 weeks ago
Joined: 10/18/2011 - 07:48
Posts: 74
Location: SE Michigan

I just picked up a TR-J10 and I’d like to soup it up like you did. How did you get the driver out? Mine has a brass ring holding down a white nylon disk which I presume is pressed up against the driver. There is a brass cap screwed into the center of the disk which covers (and compresses) a spring. There are no slots in the brass ring to unscrew it, so I assume it is press fitted. The ring does have a lip around the inside which I can slip a screwdriver under, but it doesn’t want to budge. Do I need to cut it out? Or is there at better way?

Old-Lumens
Old-Lumens's picture
Offline
Last seen: 3 years 3 months ago
Joined: 11/04/2011 - 11:39
Posts: 7478
Location: Tyler, TX, USA

I couldn't get that darned brass ring out at all. I finally used a small chisel and broke the brass ring, so it would relieve pressure and then I pried it out. I replaced it with a home made copper ring.

EDIT: I could have beaten the driver out after taking out the led, but I didn't want to hurt the driver.

My PayPal address: oldlumens (insert the @ sign here) gmail.com

My YouTube Flashlight Video Channel

The BLF Modding Links Thread 

http://imageshack.com/a/img922/1374/jQ2wdL.jpg

 

dperreno
Offline
Last seen: 6 months 3 weeks ago
Joined: 10/18/2011 - 07:48
Posts: 74
Location: SE Michigan
Old-Lumens wrote:

I couldn’t get that darned brass ring out at all. I finally used a small chisel and broke the brass ring, so it would relieve pressure and then I pried it out. I replaced it with a home made copper ring.

Dang! I wish I had your mad skills to make the replacement ring!

Old-Lumens wrote:

I could have beaten the driver out after taking out the led, but I didn’t want to hurt the driver.

I don’t want to damage the driver either.

I’m wondering if I could just use a 1-1/4 retaining ring ilo a press-fit ring. Hmmm. Home Depot says I can buy one for a buck, I may have to try that.

dperreno
Offline
Last seen: 6 months 3 weeks ago
Joined: 10/18/2011 - 07:48
Posts: 74
Location: SE Michigan

OK, I ended up using a dremel and a chisel to cut through that brass ring. It wasn’t pretty. My driver has that same tiny R300 resistor that you have, so it must be factory. Do you remember what size resistor(s) you ended up adding?