Courui D01 mod - my way (picture heavy)

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Cula
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Courui D01 mod - my way (picture heavy)

After many Courui modification posts here on BLF, thought I could also give it a try. Why not, how hard can it actually be :)?
Hope You can enjoy my build as much as I did. It was a great journey and quite a challenge.

Project cost (shipping included):
1. Courui D01 (Gearbest) – $28,00
2. Omten switch (Fasttech) – $0,60
3. Fet driver 22mm (Mountain el.) – $17,00
4. XML-2 U3 1A (International outdoor store) – $5,00
5. Maxtoch PCMCB 31,5mm (Banggood) – $4,00
6. 18650 Samsung 25R (Fasttech) – $15,00
7. Copper tube 35mm (Ebay) – $7,00
8. Copper sheet 1mm (Local hardware store) – $4,00
9. Screws 2mm (Ebay) – $2,00
10. Other supplies (Local hardware store) – $5,00

So let as begin:

1. Improving a switch.
All springs removed, preparing a copper base.

2. Cut, sanded, polished and soldered.

3. Battery compartment inside look

4. Switch side parts all together

5. Springs soldered to contact plate, 18AWG wires going trough directly to the switch. Small copper plates are soldered on the top for better contact with the batteries.

6. All sanded and polished

7. Inside look

8. Three wires from springs and one more from copper plate are soldered to one side of omten switch. One continuous 18 AWG wire is soldered from switch to three body contacts.

9. Naked original driver. Preparing it for better ground contact with the body of the flashlight.

10. Drivers battery side. Making a copper circle and the ring for better ground and battery “+” contact.

11. Sanded, polished and soldered.

12. Drilled a hole. Plan is to solder drivers “+” wire directly to copper circle below.

13. Finished and in place.

14. A look inside the body.

15. Sanding threads to gain more space for the pill.

16. Three 1mm copper circles ready for soldering

17. Soldered together

18. It looks like a big heavy coin. It took 2 hours to file, sand and polish this.

19. Ready to go inside?

20. YES

21. Inside look

22. Copper cylinders, cut and trimmed to fit inside the body

23. It is a tight fit

24. Soldered together, it’s a mess!

25. One ring to rule them all :bigsmile:

26. Another angle

27. Marking “the coin” for drilling

28. Threading holes and tightening the pill to the body

29. Coin and ring are ready to be wed. There is a coil of solder wire between them ready to be melted.

30. Married!!!

31. Another mess to be cleaned

32. You have to admit that this looks very nice.

33. Other side

34. Screwed tightly to the body

35. Inside look

36. Boring part about soldering driver to contact plate and electronic switch is skipped. The pill is alive!

37. Gasoline dedome – check, thermal paste – check. Reflector is going to sit on the PCMCB.

38. Reflector is sanded to gain clearance from the wires.

39. Sanding the body of the flashlight to lower the reflector down with 400 grid paper. It should sit on the PCMCB.

40. Sanded body and a perfect tight fit.

41. Job Done!

42. Courui D01 and my beloved ZY-T08 (http://budgetlightforum.com/node/37694#node-37694) side by side.

I will try to make some beamshots later, it is daylight now in Croatia.
Current readings also later, batteries are in the charger (unfortunately I have only two Samsung 25R-s, others are in the mail).

Cheers Beer .

Edited by: Cula on 05/30/2015 - 02:17
nitro
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Well done looks great

ImA4Wheelr
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Real first-rate work there.  Congrats on your new beautiful beast. Smile

garrybunk
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Wow!  Gorgeous! Can't wait to see some beamshots and some current readings! 

-Garry

mizjif
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WOW. Thats a lot of thought, time and hard work put in. Very impressive.

DanielM
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A real artist, very well done sir you are a real craftsman.

Old-Lumens wrote:
I love modding, but I don't have much use at all for flashlights in general.
unknown00101
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I think I've said this several times, but polished copper is just breathtakingly beautiful. Great job!

jhalb
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Winner! Mod of the Century, no, Millennium!

Cool

Man! Bravo!

Let me be the first to shake your hand. Just incredible handy work there!Wink

Any interest in selling this?

M4D M4X
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great work!

waiting for the beamshots…

find all available items in this list

i launched my new blog - all deals for members without MAP B$ Wink

 

if you want to buy a flashlight or battery for a better price: just send a mail - i will try to save you money!

downlinx
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first, WOW Shocked
second, how much extra weight did you ad there? looks like it could be used as a blunt weapon now.

BLF Community Battery Pull Thread http://budgetlightforum.com/node/32720

Cula
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Thanks guys for your comments Beer .

Did some current readings but unfortunately with only two Samsung 25R-s. So the final result should be slightly better when the third one kicks in.
Levels from 1-6:
1. 0.01 A
2. 0.07 A
3. 0.15 A
4. 0.67 A
5. 1.90 A
6. 5.01 A

I’ll upload beamshots very soon.

MRsDNF
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Speechless. What an amazing effort. Love the end product, admire your skills and wonder about the patience.Laughing

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.

 

Cula
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Beamshot 1 - Courui on the left at 5,01A, Small sun on the right at 4,85A. Pictures are taken with older Smartphone.

 

Beamshots - distance around 400 meters, it's ridiculous. Mouse over for beamshot.

tatasal
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This great mod is now added to this thread’s consolidated mod threads at the bottom of the op: http://budgetlightforum.com/node/34384

FmC
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It’s great to see another person’s take on a light that you are familiar with.

A lot of work went into this one, that’s for sure!

Well done, Cula BeerBeerBeer

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Wow, just wow! Great job!! I too love the look of polished copper! Shame to hide it in the light...

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Does anyone know how well the Courui responds to a MT-G2? Primarily I am interested in maximum throw. I know that the mt-g2 is a very large led and can be difficult to get to throw well.

Old-Lumens
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Everyone's already said it, but that is some great work. Lots of time, care and skill went into that one!

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

 

BanglaBob
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Fantastic work, Cula Big Smile

I am mightily impressed by your work. It’s super!
(…wish I had one, too Smile )

Lights out! That's when things get interesting...

Muto
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Artistry in Motion!

Carpe Noctem People! ___________
“All men are equal when their memory fades. *******************But it’s is Like it is*************
“Stay Calm, don’t be alarmed. It’s just another Holiday, Back at the Funny Farm” ………………………………….

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Found myself saying "Wow!" out loud at least 5 or 6 times as I read your post. Amazing work!!!

Cula
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jhalb wrote:

Any interest in selling this?

Thank you for your offer, maybe in near future. I have to get my hands on something new to work on before selling this one.

 

downlinx wrote:
first, WOW Shocked second, how much extra weight did you ad there? looks like it could be used as a blunt weapon now.

I Didn't weight it before but now it is 560g without batteries. It's heavy in hand.

 

MRsDNF wrote:

Speechless. What an amazing effort. Love the end product, admire your skills and wonder about the patience.Laughing

This really took a lot of patience to finish. Like 2 months of patience Laughing.

 

Tom E wrote:

Wow, just wow! Great job!! I too love the look of polished copper! Shame to hide it in the light...

Yes, it's a real shame. But it is now posted here on BLF where people will appreciate this kind of work. Good comments and a killer thrower is all I need.

 

Old-Lumens wrote:

Everyone's already said it, but that is some great work. Lots of time, care and skill went into that one!

Thanks Old-Lumens, I learned a lot from your posts and You tube videos. You are one of the reasons that I got myself into this great hobby. 

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It must be really satisfying when the solder traces polish out and just disappear 8)

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Wow that looks awesome! I love heaps of copper!!

First dibs if you ever sell it! haha

MRsDNF
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Cula wrote:
Thanks Old-Lumens, I learned a lot from your posts and You tube videos. You are one of the reasons that I got myself into this great hobby. 

Hmmm. Another one infected by OL. l guess we have something in common. Cool

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.

 

ChibiM
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I one tried to solder 3 thin round pieces of copper together, but failed miserably.

Lots of air in between and places the solder didn't flow.. also I have no real vise. Just a cheapo from eBay. (Max do a is about 4- 5cm)

Are yours totally connected with solder? And how did you do it?

jhalb
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LSX wrote:
Wow that looks awesome! I love heaps of copper!! First dibs if you ever sell it! haha

NO!!! I asked him first if he was selling it!!! So I get first "dibs"!!!Tongue Out

Cula
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ChibiM wrote:

I one tried to solder 3 thin round pieces of copper together, but failed miserably.

Lots of air in between and places the solder didn't flow.. also I have no real vise. Just a cheapo from eBay. (Max do a is about 4- 5cm)

Are yours totally connected with solder? And how did you do it?

This helps a lot when you try to solder bigger pieces http://www.banggood.com/MT100-Cordless-Gas-Soldering-Iron-Gun-DIY-Weldin...

But first you have to apply solder on both sides completely covering the surfaces. When applied and cooled, use blowtorch (or a powerful soldering iron - min 60W) to melt it again and press it so that excess solder is pushed out. I prefer using small blowtorch like one I linked above because it is much easier to heat up objects. For a few dollars you get a very good tool to do this kind of work.

n10sivern
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You did an absolutely amazing job.

Three tomatoes are walking down the street- a poppa tomato, a momma tomato, and a little baby tomato. Baby tomato starts lagging behind. Poppa tomato gets angry, goes over to the baby tomato, and smooches him… and says, Catch up.

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First DIB’s on your next piece of artistic work! J) If you ever decide to sell it! Excellent job! Wink

KB1428 “Live Life WOT”

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This is just great, i love how you took the low resistance mods to the next level here Smile

Thanks for some great ideas for future Courui D01 mods Wink

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