Small sun ZY-T08 mod II - The Next Generation

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Cula
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Small sun ZY-T08 mod II - The Next Generation
Well known flashlight, modified so many times here on BLF by members, and even by me. It was my first serious mod and since I sold it I had to get my hands on the ZY-T08 again. It is mainly a thrower, with excellent shape and dimensions, just the right size for me, with good heatsinking and a great modding potential. I got this one from FastTech and it was very nice, much better anodization then previous one and no flaws what so ever. First time I modified Small Sun I made a thrower and it was an excellent one.

This time I made a small difference….

Enjoy…

1. Small Sun, OP reflector, Maxtoch MCPCB, XHP-70 N4 3B, LD-M2 (9A), AR Lenses. What have I got myself into?

2. Dremeling inside the body to gain room for battery holder using lathe tools mounted on my bench drill.

3. One side done, time for the other one.

4. Dremeling done!

5. Car filler putty applied and inside body painted in mat black oven paint.

6. Made a 3,5mm fiberglass plate and cut contact boards using original parts to get correct shape and dimensions.

7. I’m really picking my brain at this point on how to stuff all the 18 AWG wires inside. Contacts are made from 2mm copper plate.

8. Getting there…

9. Added a central contact, wire going trough copper.

10. Other side.

11. Almost done…

12. Omten switch is mounted directly on the contact board, all i have to do is solder the wires.

13. Holder done, car filler putty applied and sanded, everything painted mat black. Rods are made of 5mm brass and bolted hard.

14. Nice looking holder. I wouldn’t have it any other way.

15. Batteries inside. I wont be using different ones, these were available at that point.

16. Works perfectly. Hope it can take 9 Amps.

17. Holder inside the body. Fits like a glove.

18. Switch side adjusting. I need to raise the lid and make space for the Omten switch.

19. Inserted a plastic washer between the switch and the rubber boot. Rubber boot will allow some squeeze when head and body are tightened together. It should provide enough force to make a good contact. For this to work, heights of the components must be spot on.

20. Epoxy putty applied and sanded to the right height.

21. Lid is extended by few millimeters. Again, painted mat black.

22. Contact board parts, 2mm copper. This should fit the cavity where the old driver was pressed.

23. Something like this. I need to wire this thing to make it work…

24. 18AWG wires going trough copper, LD-M2 needs two of them for the positive contact and one for the negative.

25. Getting there…

26. Done! Battery holder side.

26. Drivers side.

27. Inside the head…

28. Lots of debris, but you get the point. Contact board is 1mm lower then the outside lip of the head. This way the body can be tightened all the way. No worries there.

29. Reflector adjusting. OP reflector is few millimeters narrower then the original one. Epoxy putty applied, time to make it a little bit wider.

30. Carefully dremeling…

31. Lip is done. It should fit and center itself inside the head.

32. In its place. Again the height needs to be adjusted to accommodate “O” ring and 2mm AR lens.

33. Lower part of the pill is cut.

34. Upper part is sanded down.

35. Six 1mm copper circles ready.

36. Soldered.

37. This chunk of copper is bolted on top.

38. Another six 1mm copper circles prepared and one ring to hold them down. This should fit inside the pill.

39. Almost done…

40. Done! This one goes on top.

41. Another one including the ring is soldered from the inside. All combined adds to 100 grams of pure copper. That is a badass pill.

42. Happy times! Feels like Christmas.

43. Assembly day…

44. Testing phase. Moonlight at 0.02A and 5.06V.

45. Low at 0.18A and 5.30V.

46. Mid at 1.80A and 5.97V.

47. High at 8.95A and 7.24V at the emitter. Wow! I can’t ask for more, it’s a complete success!

48. Looking trough the welding glass.

49. Well centered. I’m using a custom made centering ring. That is the only thing made outside my workshop.

50. What a nice flashlight, on it’s way to be my favorite.

51. White ceiling beamshot. Cross is not visible but there is tiny dim spot in the center. Power of the XHP-70 at 9A is astonishing!

I tried to make some outside beamshots but failed miserably, it is yet for me to learn how to make decent night photos so sorry about that. There wont be any at this time.
All I can say that this is a powerhouse! I was truly blown away by the amount of light emitted from this flashlight.

Did you like my newest mod? Please comment, I’ll answer any of your questions. Thanks Beer .

dentillozie
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1 word: amazing!! im jealous at your skills

EU based flashlight modder. If you need any modding work done, make sure to PM me!

some of my mods:

- convoy meLd 4

XHP50 Maglite Mod

UF-1405 Mod

TK35 (clone) to TK35UE

giorgoskok
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Respect… Beer
Very nice mod . You did awesome work there .

pommie
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nuff said

Cheers David

Nothing to see here folks, move along...

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Wow - stunning! Everything painted and polished up like that, it has all the finishing touches.

What did you use for smoothing/polishing all that copper, plus I see even shiny aluminum?

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LoveLoveLove You are at the moment a complete unique category in BLF: taking budget flashlights and mod them so well thought-out and beautifully, while spending lots of time on the job, that they become works of art!
Cula
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Tom E wrote:

Wow – stunning! Everything painted and polished up like that, it has all the finishing touches.


What did you use for smoothing/polishing all that copper, plus I see even shiny aluminum?

Beer .

Up to 2000 grit 3M sand paper and then Autosol metal polish. It a messy job, my hands were greenish for days.

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Outrageously awesome work there! Very well done, no detail left out. Your final finish and fit is just exquisite! Such patience, and obviously you put a lot of thought into where you wanted to take it.

Well Done!

Dale

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djozz wrote:
LoveLoveLove You are at the moment a complete unique category in BLF: taking budget flashlights and mod them so well thought-out and beautifully, while spending lots of time on the job, that they become works of art!

Thanks djozz for your kind words, I’m especially proud of this one. It was the hardest one I made so far.

DB Custom
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That one should be in the Old-Lumens Hand built challenge, you’ve got plenty of documentation in photo’s, give the a shout out and see if you can add it in…

Dale

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How does the beam compare to your JM30?

I’m really quite jealous. I can make some bright lights, but they’ll never be as finished and beautiful as this

My Favorite Modded Lights: X6R, S8 , X2R , M6, SP03

Major Projects:  Illuminated Tailcap, TripleDown/TripleStack Driver

Cula
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DB Custom wrote:
Outrageously awesome work there! Very well done, no detail left out. Your final finish and fit is just exquisite! Such patience, and obviously you put a lot of thought into where you wanted to take it.

Well Done!

Thanks Dale, I learned a great deal of things about LED’s and Flashlights reading trough your posts and builds Beer .

DB Custom wrote:
That one should be in the Old-Lumens Hand built challenge, you’ve got plenty of documentation in photo’s, give the a shout out and see if you can add it in…

Don’t know if I can qualify since this is production flashlight.

Cula
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pilotdog68 wrote:
How does the beam compare to your JM30?

I’m really quite jealous. I can make some bright lights, but they’ll never be as finished and beautiful as this

It is far more brighter and smoother, the tint is also to my taste. Something between moderate thrower and powerful flooder but no hotspot in the distance. It is a bigger and deeper reflector then that one in JM30 which is quite shallow. JM30 is a pure flooder.

Yourrid
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The polish job on the copper alone is incredible! WOW! Beer

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Did some beamshots, they are crappy ones taken from a cell phone. Sorry but I couldn’t do any better ones with this camera.

1. Control picture – distance around 70 meters

2. High (9 Amps)

3. Control picture – distance around 25 meters

4. High (9 Amps)

I’ll do some Head/cooling fins temperature measurements tomorrow and post the results.

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Wooow just Wooow i imagine the time taken just to redesign this flashlight, nicely done, you made me really wanting to remod mine, also i haven’t seen an awesome modding like this in a while and yes as you said Next Generation Thumbs Up

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Incredible!

Great work.

Carpe Noctem People! ___________
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Sorry, but of course it doesn’t qualify because it’s a production flashlight, but I got so caught up in how drastically you changed it I lost track of the small details of the scratch build thread. lol

Dale

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Shocked Beautiful work Cula!!!

My gratitude to those who are willing and able to help others (in whatever way you can)! Being human is more than just existing for yourself. Smile

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Orsm mod. I’m looking forward to seeing this on the big screen when l get home.

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.

 

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Nice!!!

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Looks beautiful! Very neat work, and apparently with minimal tools. I would have assumed that a mill was necessary. And all that mirror polish and smooth paint is on the inside.

Flashlight designers should look at lighthouses and pottery.
这些谁设计的手电筒应该看灯塔,以及在陶器。

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Wow! Justin once tried to interest the forum in a contest to mod an existing light.. This would have been a slam dunk winner.

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

Scott

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Very VERY nice, all those details!
Awesome beamshots (and some nice trees you see there)
Maybe some sort of modding contest could be organised to follow up the build from scratch contest (though we already have a winner Big Smile )

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great work . do you have a link to the reflector you are using

Cula
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Thanks guys for your comments Thumbs UpBeer .

lostheplot wrote:
great work . do you have a link to the reflector you are using

Of course.
http://www.kaidomain.com/p/S021809.55_5mm(D)-x-32mm(H)-OP-Aluminum-Reflector

Emitter hole is only 8mm. You need to make it wider to fit the XHP-70. Also the base is flat so you have to grind enough aluminum so that it doesn’t shorten the led wires. Luckily, there is enough “meat” to grind, it is pretty thick at the bottom.

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Do you have a picture of your dremel setup? You do great work and yet it looks like you do not have any extravagant equipment.

Rufusbduck
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He says “dremel” but also says it’s a milling bit (end mill?) mounted in a drill press which the picture shows, looks like it could be a Bosch.

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

Scott

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Very very nice&big job, well done!
I have thinked many and many time to pull the trigger on the Small sun ZY-T08 because it is a very nice torch and I like so much the form factory…but I’m not able to do anything you doit so well Facepalm

May can I ask you a little more of work? When you can/if you can, do you can make a small video? A coupple of minutes will be enough, because on Youtube the Smallsun is missing (only a very short&poor video) to show the power&beauty of this light. Thanx again! Thumbs Up

www.youtube.com/channel/UCeDhMPm0L1yvr3LpygDPgMw my flashlights/knives/gear video reviews
www.absoluteblack.net my dark comics

Cula
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LightRider wrote:
Do you have a picture of your dremel setup? You do great work and yet it looks like you do not have any extravagant equipment.

Maybe my English isn’t so good and it looks confusing so I apologize for that. Electric tools used in all my builds are bench drill, simple dremel tool which you can buy for $20 and bench grinder. I buy affordable drill bits (like the one in picture No. 30) mainly from Banggood and use them for drilling, grinding and dremeling. Rest is done using hand tools like all kinds of hand files, scissors for metal etc. As you can see these are all common hobby tools that every average workshop have. Wish I had a lathe, things would be much simpler but I don’t have a place for it. It is a small workshop in my basement.

Rufusbduck wrote:
He says “dremel” but also says it’s a milling bit (end mill?) mounted in a drill press which the picture shows, looks like it could be a Bosch.

Yes, it is a Bosch, my workhorse.
https://www.bosch-do-it.com/gb/en/diy/tools/pbd-40-3165140569163-199903.jsp

Drill bits used for my builds:
http://www.banggood.com/5pcs-4681012mm-4-Flute-End-Mill-Cutter-HSS-Strai...
http://www.banggood.com/3pcs-3-124-124-20mm-HSS-Titanium-Coated-Step-Con...

Cula
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Manx wrote:
Very very nice&big job, well done!
I have thinked many and many time to pull the trigger on the Small sun ZY-T08 because it is a very nice torch and I like so much the form factory…but I’m not able to do anything you doit so well Facepalm

May can I ask you a little more of work? When you can/if you can, do you can make a small video? A coupple of minutes will be enough, because on Youtube the Smallsun is missing (only a very short&poor video) to show the power&beauty of this light. Thanx again! Thumbs Up

Hello Manx,

I never thought about making the video review. It would be a whole new ball game for me. If I get the chance/time I’ll try Thumbs Up