CRX Magnetic Brass Art - 2016 4th BLF Scratch Made Light Contest Winner

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CRX
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CRX Magnetic Brass Art - 2016 4th BLF Scratch Made Light Contest Winner

CRX's Magnetic Brass Art

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Winner of the BLF/ Old Lumens Scratch Made Light Contest 2016

And also the

People's Choice Award

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Description:

My build will consist of numerous parts made with the use of small hand tools only except where absolutely necessary i will use a small rotary tool.

It is going to be a small compact kit where each part compliments the other.

(I hope the judges are weary of those big builds Innocent )

Each part will be in it's own section as linked below.

Not all parts will be flashlight associated but you'll see how they come together as the building continues - stay tuned...

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Part One - Brass Trench Lighter

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Part Two - Brass Mini Lantern

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Part Three - Brass Pocket Bellows & Ferrocerium Rod

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Part Four - Brass Battery Charger/ UV Light

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Part Five - Brass Dual Rechargeable Flashlight

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Part Six - Brass Sliding Double Pill Container

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Part Seven - Brass Utility Knife/ Repair Kit

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Part Eight - Brass Carry Case


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Part Nine - Striker/ Blade Sharpener

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Part Ten - Magnesium Container

 

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 The Pieces

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Total Time - 88 Hours

Total Parts Approx - 214

Total Weight - 320g

Dimensions - 84mm x 74mm x 22mm

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Materials & Tools Used

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 -stevi-

Edited by: CRX on 12/31/2017 - 23:25
CRX
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Part One – Magnetic Brass Trench Lighter

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This mini brass trench lighter is held together by strong neodymium magnets and friction.

Powered by refined lighter fluid or almost any combustible liquid in a pinch.

Made from 15/32” (11.9mm), 7/16” (11.1mm), and 13/32 (10.31mm) brass tubing and 0.5mm brass sheet.

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Height – 40mm
Depth – 12mm
Weight – 20 grams

Parts – 21
Time – 10 Hours

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Firstly i had to salvage the parts i cannot make, the flint wheel, wick and flint post from old lighters

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Cut 7/16” (11.1mm) brass tube & plate

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Filed brass disc into shape

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Mark out and drill hole for flint post

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File out to snug fit

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Drilled hole for flint wheel pin

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Filed in slot to accomodate striker wheel

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Sanded down with 600 grit wet & dry paper

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Installed wheel with brass pin, compressing slightly with vice grips for friction fit

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Sanded down flush

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Cut spring down and installed flint & brass plunger with modified end cap

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Cut 7/16” (11.1mm) brass tube and drilled disc for lighter wick

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Cut and drilled bottom brass disc and 13/32 (10.31mm) insert tube, this will be cut in half making a removable cap held in place by the flint screw

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Soldering the end cap disc into place in fuel insert tube

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Installed brass tube to hold brass end cap and magnets before soldering

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Cut two lengths of 15/32” (11.9mm) tube to 20mm, two brass endcaps and 7/16” (11.1mm) inner seating tube

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Installed 2×10mm neodymium magnets in top & bottom cap section, these will stick to the top of the flint wheel and the magnet on the fuel canister end cap

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Top & bottom outer casings soldered, sanded with 10mm magnets installed

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Soldered flint post into place in fuel canister

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Made fuel canister end cap with 13/32 (10.31mm) tube and 4×2mm neodymium magnet epoxied on, this will stick to the magnet in the tail cap

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JB weld in fuel canister end cap to hold replacement flint/ plug but still allow refuelling

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Bottom view empty fuel canister

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Top view

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Putting the fuel canister together

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Fueling up

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Spare flint/ fuel plug installed

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Thumbs Up

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Size comparison

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Top cap can stick to end cap for use

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Finished

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Part two coming up…

Thanks for looking.

CRX
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Part Two – Mini Brass Magnetic Lantern

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This mini brass lantern is twist switch operated, held together by the use of strong neodymium magnets and friction.

Powered by a 10180 cell it will operate for more than 70 hours continuous use.

Made from 15/32” (11.9mm) and 7/16” (11.1mm) brass tubing and 0.5mm brass sheet.

After experimenting with various resistors i found the best light output/ runtime for me to be achieved with a 1000 Ohm SMD resistor soldered in line with the positive line of the LED’s.

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Height – 40mm
Depth – 12mm
Weight – 16 grams

Parts – 26
Time – 12 Hours

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First part is the switch mechanism.
My vice is setup with two small magnets on opposing sides to give a consistent offset cutting angle, this will create a contact break of the cell when twisted, a gap of about 0.7mm

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Exaggeration showing the angle cuts i want to achieve

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Final position

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Brass disc and tubes cut to rough size
Tailcap shell, inner lower switch & battery tube upper switch part

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Switch Detail showing how the angle cut tubes close or create a gap when twisted

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Tailcap brass disc filed into shape

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Soldered in place with solder paste and a jet lighter

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2×10mm magnets and small angle cut tail switch part installed

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Markings showing how the mechanical switch operates.
The lantern is held together by friction and the force of the magnets.
When twisted to the off position the tailcap magnet loses contact but still exerts enough pull to keep the light together.

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Cutting of press fitted tail contact copper disc

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10180 cell in tailcap section with both switch parts

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Making of temporary positive insulator disc to keep epoxy in place for positive magnet contact

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Soldered four 5×1mm magnets together for positive contact

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Magnets and insulator disc fitment prior to epoxying in place

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Showing how the magnets will contact the 10180 cell

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I considered a few different LED setups, XM-L2, UV, straw hats, SMD’s, XP-G2’s

This one with XP-G2 LED’s is interesting i thought

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I decided to go with two 3mm SMD LED’s soldered back to back

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Negative lead soldered into battery tube

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102 SMD, 1000 Ohm resistor should give around 0.8mA supply current.
Approx 70 hrs continuous runtime from 10180 cell. This is soldered to the positive battery contact.

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Initial test

Thumbs Up

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For the lantern window 10mm acrylic tube cut to rough length

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Wrapped kapton tape around ends and filed out groove for where the LED negative contact joins the battery tube

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Opposing head magnets epoxied together and wrapped in kapton tape

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Window measurements & head fitment

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Magnets installed in head & epoxied in place

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Tailcap with press fitted copper disc, 2× 10mm magnets underneath

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Magnets in head are stronger than tail magnets for easy cell removal

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Inside head showing stacked magnets – positive contact, epoxied in place, temp insulator disc removed

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Cut brass disc for head

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Tritium vial installation in head

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Switch Operation – Off

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Twist On – All Good

The magnets top & bottom give a nice relflection of the light.

I am considering lighlty sanding the window to give a more even diffuse light – suggestions?

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The acrylic tube running the full length of the head gives a nice illuminated ring effect on the top of the lantern with the trit in the centre.

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Finished

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Part three coming up…

Thanks for looking.

CRX
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Part Three – Brass Fire Straw & Ferrocerium Rod

If you haven’t guessed yet, this is a small camping/ outdoor kit.

In this part i have made an extendable fire straw or pocket bellows (used for blowing on embers made with a ferrocerium rods sparks to get a fire going, it’s a very useful piece to have in your kit)

Powered by, however much puff you have left in you Wink

Made from 15/32” (11.9mm), 7/16” (11.1mm), 13/32 (10.31mm), 3/8” (9.52mm), 11/32” (8.73mm), 5/16” (7.94mm), 9/32” (7.14mm) and 1/4” (6.35mm) brass tubing plus a 75mm x 6mm ferrocerium rod.

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Length – 80mm – 285mm
Depth – 12mm
Weight – 44 grams

Parts – 28
Time – 8 Hours

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All brass tubes laid out, measured and marked ready for cutting with junior hacksaw

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Five 81mm tubes cut along with corresponding slide stop rings

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Sanding rings flat, deburring and lapped down to 4mm

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Ready to start playing around with how i’m going to put this together

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Rings epoxied in place on ends

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Rings for mouthpiece end cap disc

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Internal rings fitted and striker rod made with epoxy and graphite

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Fitted together, end cap epoxied in place, ends filed flat and alternately blackened

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Ferrocerium rod slightly protrudes to enable easy press removal

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Showing operation

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Rod flips around and inserts back into tube creating a handle for ease of use.
The rod butts up against a same sized tube in the core so won’t slide back up the handle

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With the rod removed it can be pushed into the other end (brass first) thus pushing on the core and so slides out the extendable parts

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Fully extended it measures around 285mm – enough for maintaining eyebrows, lashes etc Wink
It is surprisingly airtight, i could detect no leakage from the joints

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Collapsed to 80mm, keeping in line with the other units

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Looked a little plain to me so i marked lines round with calipers at 20mm intervals, taped up and gently cut in with junior hacksaw

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Finished

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Part four coming up…

Thanks for looking.

Ouchyfoot
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For Lease

Firelight2
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You’re making a brass blowgun / flashlight that shoots nuts and bolts if you blow hard enough? Blushing

CRX
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You got it Silly

CRX
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Ouchyfoot wrote:
For Lease

How much?, i might need it LOL

MRsDNF
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Someone here has an idea what there doing? That’ll be the day. Facepalm Smile

 

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.

 

FmC
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Good luck, I have no idea what to do this year… No different from the last few times really…

MRsDNF
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Thats the spirit FMC.

 

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.

 

luminarium iaculator
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Gatling flashlight style each sourced with fet driver and one 18650 cell?

We’ll see Smile

ImA4Wheelr
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Hmmm, sounding interesting already.

Rufusbduck
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Big Smile Brass makes me smile.

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

Scott

jhalb
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Definitely a winner here! This is going to blow some socks off!! Beer

Old-Lumens
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Looks very interesting and possibly very tiny. Thanks for being in the contest this year.

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
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Just WOW. That is the hottest light I’ve seen here for awhile. Its smokin. Thumbs Up

 

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.

 

FmC
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I just sat here for 5 mins with my mouth open….

10 hours? – can I borrow a little of your spare time please?

Beer

Rufusbduck
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Oh my, I wish there was a gofundmyimagination site where others could borrow some of that stuff.

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

Scott

MG
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Brass is good. Great pictures too.

Need some sort of ____-fire name for it.

CRX
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Old-Lumens wrote:

Looks very interesting and possibly very tiny. Thanks for being in the contest this year.

Thanks OL

Rufusbduck wrote:
Oh my, I wish there was a gofundmyimagination site where others could borrow some of that stuff.

I thought it was here… Smile

MG wrote:
Brass is good. Great pictures too.

Need some sort of ____-fire name for it.

Certainly Not! LOL

Rufusbduck
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It’s worth the time it takes for the pictures to load. A few words of text with the pics would help figure out which end we’re looking at. Fun puzzle figuring it out. This one reminds me of when I could still see small. Congratulations!

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

Scott

CRX
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You’re too kind, thanks.

Added brief descriptive text to images.

DavidEF
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I can see we have another Brass Master in our midst! Seriously, CRX, your build is indescribably awesome already, and you still have parts three and four to go! Shocked

The Cycle of Goodness: “No one prospers without rendering benefit to others”
- The YKK Philosophy

freeme
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My favorite entry so far. Do you intend to polish the surface?

©freemex1thedeals.com

CRX
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Thanks, yeah there’s still final tweaks, sanding and polishing to be done, i might even make them all black – just kidding! LOL

I was thinking of giving the acrylic window of the lantern a sanded/ brushed finish for a more diffuse light output – opinions welcome on that.

pinkpanda3310
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Oh, I feel so outclassed and you’re only half way. Awesome work CRX.

For the diffusion try a bit of tape first to see if you like it. Maybe have some funky design on the tape (inside the tube)…? Just a suggestion.

CRX
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Good idea, thanks pink.

Rufusbduck
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Or cut a negative, stick it on, spray paint, then remove the negative. Sort of like OL’s flame Mag.

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

Scott

MRsDNF
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You sir are a mad nutter. Where have you been hiding this skill? This is coming along beautifully. I may have to steel your Plasticine idea sometime. Smile

 

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.

 

ImA4Wheelr
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Wow! I’m in awe of your imagination and talent.

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