Warsun X50 Mod - a complete makeover (Beamshots added)

17 posts / 0 new
Last post
Cula
Cula's picture
Offline
Last seen: 1 hour 2 min ago
Joined: 11/14/2014 - 02:04
Posts: 317
Location: Croatia
Warsun X50 Mod - a complete makeover (Beamshots added)

Love the looks, size, battery versatility and I mostly love the price of this flashlight. Selling at $14, I had to have it. But it is a zoomie and I’d have to stretch it very far to say that it is a good one.
I had no interest in this flashlight as a zoomie and then my brain started to work overtime. Last few months was all high CRI Nichia here on BLF so I had to use these fine Led’s and work something out. This time I managed to keep everything at the budget side.

So let’s start and see if you like this mod as much as I do.
Project cost:

1. Warsun X50 – $13,39 (Banggood)
2. Triple Nichia 219C (4000k) 90 CRI – $7,87 (Kaidomain)
3. 3 × 16 mm XP MCPCB – $4,47 (Kaidomain)
4. LD-3 9A driver – $15,00 (Led4Power)
5. TIR optics from Ledil – $10,00 (Local web store)
6. Copper, switch, boot, wires, etc. – $10,00

1. Warsun X50

2. Disassembled. Bad design. Lightweight and hollow pill. One MCPCB on top of the other MCPCB. Pill is not making any contact with the body of the flashlight. I’ll have to completely rework this to improve heatsinking.

3. Switch mod parts. Only thing that is worth is the omten switch.

4. I managed to ruin the threads on the original switch retaining ring (very thin and soft aluminum). Luckily, I had one old Ultrafire flashlight that had the same threads at its brass drivers pill.

5.Brass driver pill cut, sanded and reworked into a retaining ring for my Warsun.

6. Almost done.

7. Switch mod complete.

8. Hope this omten can take 9 Amps.

9. Switch tightened. The threads are holding. Looking good.

10. Drivers pill mod parts. I reused the bottom part of the Ultrafire pill to hold the 17mm LD-3 driver.

11. Stripped driver’s PCB, brass ring and copper plate mash-up.

12. Driver’s pill done.

13. Other side.

14. In its place.

15. Aluminum pill top is cut.

16. Made a 3mm aluminum plate to fill the void.

17. Aluminum plate brazed from the inside.

18. Top sanded and finished. Stage one complete.

19. Copper ring cut to fit inside the flashlight body.

20. Tight fit. At this point I realized that battery tube fits inside the copper ring.

21. So I made a bigger ring.

22. Cut and reworked to fit.

23. Another tight fit.

24. Bottom side. Copper ring all the way in. The “step” inside the flashlight head stops the ring to go any further.

25. Top side. I made one copper plate. It sits on a battery tube below.

26. Big copper rod chunk, courtesy of kiriba-ru, received few weeks ago. It is time to put it in good use.

27. Pill parts cut and sanded to fit.

28. Everything soldered. Hope I can pull it out of the head.

29. Cleaned and sanded.

30. Other side.

31. Pill drilled, threaded, sanded and polished.

32. Aluminum pill bolted inside the copper pill.

33. Battery tube screwed between two pill’s.

34. Inside the head. This turned out very nice. Executed like this, majority of the heat from led’s should sink properly trough the head instead trough the battery tube.

35. MCPCB’s cut to fit inside. Also made a triangle holder for TIR optics. It is the same height as those MCPCB’s. That is going to ensure the correct distance between the led’s and TIR optics. Convoy L6 centering rings are there to help me center little Nichias. I’ll remove them later.

36. MCPCB’s fixed with arctic alumina epoxy.

37. Inside the head.

38. Driver wired. Ground wire bolted.

39. Nichias wired.

40. Battery tube along with the pill are not fixed to the head of the flashlight. Had two solutions for this problem – gluing or bolting. I like flashlights that can be disassembled (for servicing purposes if needed) so I chose bolts.

41. Final touch. I had to do it.

42. Now it is done!

43. Three eyed Warsun.

44. Tailcap decoration. Pill bolts painted mat black.

45. To get the perception of the size. From left to right – Convoy S8, Warsun X50, Jaxman X1, Brynite B158 and ZY-T08 Small Sun.

46. Glow in the dark tape inside the head.

Tailcap measurements (26650):
Moon – 0.01A
Low 1 – 0.13A
Low 2 – 0.64A
Med – 1.62A
High – 3.14A
Turbo – 8.95A

As you can see, everything worked out great although I wasn’t sure I could finish this one. It was a struggle all the way. But the reward is another beautiful performer. You can run this puppy hard, heatsinking works pretty good. 26650, 18650, 3xAA, the choice is yours. Love it!

I’ll try to make some beashots tomorrow, of to bed now.

Did you like my newest mod? Please comment.

Cheers

Edited by: Cula on 03/13/2017 - 05:23
FmC
FmC's picture
Offline
Last seen: 4 hours 35 min ago
Joined: 03/31/2013 - 05:23
Posts: 1846
Location: AU

Very nice conversion. Are you running low on copper yet?? Silly

Love your mods Beer

itsonlyme
Offline
Last seen: 2 months 1 week ago
Joined: 02/21/2015 - 10:05
Posts: 543
Location: Uk

Wow, just wow

CRX
CRX's picture
Offline
Last seen: 1 day 6 hours ago
Joined: 04/02/2013 - 15:27
Posts: 1939
Location: Scotland

Nice work Thumbs Up

Cula
Cula's picture
Offline
Last seen: 1 hour 2 min ago
Joined: 11/14/2014 - 02:04
Posts: 317
Location: Croatia

FmC wrote:
Very nice conversion. Are you running low on copper yet?? Silly

Love your mods Beer

Almost out, just few more builds Big Smile .

martook
Offline
Last seen: 3 days 20 hours ago
Joined: 01/24/2016 - 09:11
Posts: 149
Location: Sweden

Impressive work! Any idea how many hours went into the build?

Pidro
Offline
Last seen: 1 month 2 weeks ago
Joined: 07/04/2016 - 17:01
Posts: 27

@ Cula
How did you remove the pill?

The Miller
The Miller's picture
Offline
Last seen: 38 min 33 sec ago
Joined: 12/14/2015 - 12:08
Posts: 8237
Location: Charente France

Nice mod!

Slayer1
Slayer1's picture
Offline
Last seen: 4 hours 3 min ago
Joined: 03/03/2016 - 02:59
Posts: 100
Location: Singapore

Awesome great mod as always!!

Modded Shadow JM30. Sigma Custom Brass 18650 219C with the works. Sinner's Copper 18650 219B. Imalent DN70. Olight S1. Reylight Pineapple 219CT 4K R9050, Convoy L2/L6/C8/M1/S2. Maglite XL100. Surefire 6P/9P, Emisar D4 219C 83CRI 5000K, Barbolight V-04 NKD.

hayyam
Offline
Last seen: 4 days 12 hours ago
Joined: 02/02/2016 - 15:28
Posts: 6
Location: Germany

wow-bad ass flashlight:-)!!!

Lopan
Offline
Last seen: 4 hours 58 min ago
Joined: 08/02/2014 - 22:23
Posts: 55
Location: Germany

Awesome mod. Can’t wait to see the beamshots.

Pidro wrote:
@ Cula How did you remove the pill?

Hit it from the driver side to loosen it.

Cula
Cula's picture
Offline
Last seen: 1 hour 2 min ago
Joined: 11/14/2014 - 02:04
Posts: 317
Location: Croatia
Pidro wrote:
@ Cula How did you remove the pill?

What Lopan said above. Find a socket wrench or something similar and hit the pill with hammer from battery tube towards the head of the flashlight. I held my flashlight in my hands to prevent any damage. It gave up after several heavy hits.

martook wrote:
Impressive work! Any idea how many hours went into the build?

This is easily 25-30 hours of work stretched over 15-20 days. The main problem with this kind of complicated build is that you can’t predict everything (like clearance issues) when ordering parts. When something doesn’t fit like it suppose to it becomes frustrating and expensive project. Completing a complicated build requires a lot of patience.

wolfdog1226
wolfdog1226's picture
Offline
Last seen: 3 weeks 5 days ago
Joined: 10/09/2013 - 20:47
Posts: 1204
Location: Acquasanta,Italia/ Valley Forge, Pa.

Great job along with your pictures and explanation of your mod. A lot of hard work results in a very nice reward!

I am NOT mechanically inclined like yourself, My brother and numerous friends.Maybe I am not suppose to be because I do not think I would have your patience when difficulties and changes are needed to complete the mod!

A liar will eventually get entangled in their own web. The satisfaction of that alone is all the revenge one needs.

***                                                                                       ***                                                                                    ***

 A people pleaser is one who is searching for acceptance in ALL the wrong ways.                                                                                                                                                                                                                                                                Wolfdog-6.16.2017

ImA4Wheelr
ImA4Wheelr's picture
Offline
Last seen: 4 days 19 hours ago
Joined: 02/03/2013 - 14:51
Posts: 7344
Location: SC

Love it.  I bet the light feels much more substantial in hand with all that beautiful copper.  There is a very special feeling when you use a light like this.  You built it.  You know what is happening electrically, thermally, etc.  You can feel the heat coming to the surface rapidly (after all that copper mass first takes the heat it wants).  You see no signs of thermal sag.  etc, etc.  It's special enough in itself to justify the time and cost.  Even though the time and cost were not to make the resultant light, they were hobby time.  A special time, that in and of itself, is the end and not the means.

". . . You realize that wasn't really a loss for me in Africa — it was a gain that I didn't appreciate."

- George Foreman 2017

MRsDNF
MRsDNF's picture
Offline
Last seen: 1 hour 1 min ago
Joined: 12/22/2011 - 21:18
Posts: 11141
Location: A light beam away from the missus in the land of Aus.

Nice build Cula. Thumbs Up
You can see the hours you have put into this in your pictures.

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
Cula's picture
Offline
Last seen: 1 hour 2 min ago
Joined: 11/14/2014 - 02:04
Posts: 317
Location: Croatia
ImA4Wheelr wrote:

Love it.  I bet the light feels much more substantial in hand with all that beautiful copper.  There is a very special feeling when you use a light like this.  You built it.  You know what is happening electrically, thermally, etc.  You can feel the heat coming to the surface rapidly (after all that copper mass first takes the heat it wants).  You see no signs of thermal sag.  etc, etc.  It’s special enough in itself to justify the time and cost.  Even though the time and cost were not to make the resultant light, they were hobby time.  A special time, that in and of itself, is the end and not the means.

Nicely said ImA4Wheel Thumbs Up .

As usual, my crappy beamshots Facepalm .
White wall beamshot doesn’t show but there is a nice hotspot and a spill. There are some “artifacts” on the far edge of the spill but only seen when white wall hunting and looking very closely. It is not a thrower or a monster flood flashlight but what it lacks in power (compared to triple XP-L or XM-L2) it certainly compensates with beautiful tint.

Mike C
Mike C's picture
Offline
Last seen: 15 hours 36 min ago
Joined: 01/22/2014 - 08:03
Posts: 1612
Location: Sweden

That a serious mod you did there! Nice work!