Pure Machining Porn! Image Heavy. Ending

Flashlight Modding and DIY Parts
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I thought it was time to share some machining images... building 7 of these and talked sweet thing into pushing the button on the camera a few times. These are just various stages of the process on the first couple. I'll try to add some more as I can. Enjoy!

Some just cut off at the saw... other chunks well on the way.


Ready For Threads...

like magic!

Looks about right.

Facing off the other end...

Making room for the boring bar....

I managed to grab another image... This was taken last week. I had to install a new hot water heater...and go see a customer... back at it this week.

Electronics installed on one. One more to go. Then it is time for heads and tails!! These are just three mode... lo-med-high. The pill is partially screwed in here so you can see. Five more screaming to get started.

10 /17 update!

I am behind on the postings... hang in there with me.

Worked on the heads for the lights last week...

Bored the inside to the proper minor diameter for threading. 1.216" was the target... got close!

I have to take out a little in the front for o-ring clearance. about .022". EDIT.... .032" deep. This keeps the o-ring from rolling around when the head is screwed on.

There always seems to be a lot of interest and questions about threading. Here are the two internal threading tools I use the most. Notice the inserts face opposite directions.

Using the tool on the right in the image above, the stock rotates toward you standing at the lathe as the purple arrow shows. The tool starts from the outside of the stock and cuts the threads as it moves inward as the yellow arrow shows. This is the "Standard" way to cut threads. Good...but can be a little daunting sometimes if you are cutting to an internal shoulder...or as called "Blind Hole". Easy to crash a machine doing this.

The tool on the right two images up cuts just the opposite of the one above. The spindle is reversed, and the stock rotates away from the lathe operator as shown by the purple arrow. The tool cuts the threads from the inside out as the yellow arrow shows. This can save a tool and part when threading to that internal shoulder or blind hole. As well... there is no hurry in dis-engaging the threading lever. Much easier!

Another benefit is that most of the time uhhh.. sometimes...ummm...now and then when it wants to, the tool pulls out the swarf when it comes out. This is nice when it happens!!

So... you end up with this...

They really need to screw together!! Where is that pipe wrench??

Need a hammer over here!!!! Big One!!!

OK... here are the ending images for this line of flashlight / machining porn. I shot these images a week or so ago but have been covered up in the shop. This is the original light and two new ones. I hope you have enjoyed the little journey as much as I have taking you along. Thanks to each of you for putting up with me!

Looking down the barrel!

I dislike the green tail covers but the buyer is the boss.

They make light! Who would have thought!

They even work in the dark!

They work after hours too!

They stand up...

And... stack up to some point. ...

more of these to build... I can almost do it in my sleep.

Thanks For Looking.

Ending here for now. TL





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stunning! how cool must it be to create your own lights.

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Nice. You can use a lathe manually? You are full of surprises and talent. What components are going into these? Do you have favorite reflectors and drivers etc you like to use and keep those pics a coming.

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beautiful….

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Nice!

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How do you cut threads by hand like that? Is there something that guides the spacing? I assume so.

I want to get a lathe when I retire, tons of projects floating in my head.
:smiley:

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Very nice indeed!

How difficult would it be to turn your own thick square-cut threads? I dont think Ive ever seen anyone attempt it with their custom lights.

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I assume he engages a gear which advances the tool at a constant speed.

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I am a P60aholic and that looks awesome. Wish I was one of the 7!

Matt

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I put my name down on the list for one and came first in line. Cant wait to get a bit of TL orsmness.

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Great…

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Very nice! Thanks for sharing :slight_smile:

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You have to be really fast! No, it looks a lot harder than it is. Lathes work different from one to the next. But on a manual lathe it all comes down to the fact that either with belts or gears...or a combination of those, you set the "Timing".... or gear ratio, (whichever makes more sense to you) of the gears and lead screw. On mine, I simply set 4 dials to ratio the gears... and then engage the thread dial on a given number...or set of numbers. These settings will vary depending on the thread pitch... or threads per inch you want to cut. Lathes generally have a metal chart attached to the machine, telling you where to set each dial to get what you want.

It sounds much more complicated than it is. I have always said that the hardest part of threading on a lathe is buying the right tooling. Once you cut threads a couple of times...it all comes clear as to what is going on. I'll add some images to the original post this evening or tomorrow that might help. ... TL

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It isn't hard. It just takes a different shape tool and technique. To my knowledge, from the typical supply house, you can't buy the tool... it has to be hand ground. The square threads are cut at a faster speed...and a much lighter depth per pass as you have a lot more tool going into the material itself. The touchy part is setting the spindle speed and tool depth per pass so that you get a perfectly clean bottom in the threads for the matching part to run on when putting them together. The harder the material... the easier it is to cut square threads... or at least that has been my experience. TL

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I am shocking!! The lady of the house says that a little different...but we'll go with shocking. These get a Q-lite driver 3.04 amp and the XM-L2 U3 LED. I am using the reflectors from Illumination Machines. Their faceted XML-10. I'll add some more images perhaps this evening and try to include a reflector.

You could come & help!!! TL

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I'd love to come and help. Just not this weekend as the biggest car race in Aus is on this weekend so the couch needs a lot of attention. I'm looking forward to the extra pictures. You just cant have to many of them.

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Added one new image in the original post. Hopefully, more this week!! TL

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Thanks.

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Solid state construction!

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Don't you guys in Texas have anything better to do than make us drool??? I have to bring a towel to my desk every time I open one of these threads :) Makes me feel like a Bordeaux at feeding time!