DBC-05 Triple XHP-50.2 Scratch Build

74 posts / 0 new
Last post

Pages

DB Custom
DB Custom's picture
Offline
Last seen: 5 hours 5 min ago
Joined: 01/13/2013 - 22:28
Posts: 14969
Location: Heart of Texas
DBC-05 Triple XHP-50.2 Scratch Build

As is the case so many times there were a couple of reports of new stuff here that I just had to try! Smile djozz reviewed the new XHP-50.2 and TexasLumens was looking at the 20700 cells, so I figured I’d build a light and try both of those at once. This is my 5th full build from scratch, hence the name, and while I’m still on the learning curve with the lathe I think it’s working out pretty well.

Initially I made a battery tube from thick walled 6061 Pipe that would easily hold the 20700 with room for the 21700 when those become available. Getting the light completed to a fair simile of the design showed me that I needed to make some changes.

Here’s the design…

I don’t have autocad abilities so this is mocked up in Photoshop to scale.

I ordered the materials, including a 3.17 pound chunk of Tellurium Copper for the head. First draft, getting the knurling on the tube and getting the copper semi sized to fit the triple reflector from KaiDomain. Since I didn’t have the reflector and emitters I wanted to just get it close first, to save some time later when the other parts arrived…


As you can see, I was trying to utilize some pieces I already had here, so I mated the larger diameter aluminum bar stock to the top of the Te/Cu to accept the 63.7mm reflector. ( the Te/Cu was the largest diameter piece I found at my supplier online)

Then I did about 90% of the stock removal in the copper for the big reflector…

So, I’m really bad about finishing a project in one continuous process so I don’t forget what I’m doing, but in this case the above parts were set aside and I had to wait a couple of weeks for parts to arrive. A lot went on in the meantime, including a 1600 mile trip out of state to shoot photo’s of my nephew’s wedding. When we got home, parts had arrived! I jumped right on the light, (they were on their honeymoon, figured they had other things to worry over than pictures!!)

And this is the initial result…

The triple XHP-50.2’s made numbers like this with the 20700B (the high capacity version of the Sanyo cell, the A variant wasn’t available)

0.18A for 122.13 lumens
0.42A for 333.96
1.22A for 941.85
4.67A for 2839.35
9.01A for 5147.46
15.25A for 7866
with a 30 sec showing of 7728 lumens

I then bypassed the spring on the driver and got it up to 20.34A and 9108 lumens. Still a long ways from what I had though this new emitter might do.

So I machined a copper spacer to act as switch retaining ring and got it up to 10,488 lumens with a 30 sec showing of 10,005 lumens

Hmmmm, still not there. So I tried a pair of Sony VTC6 cells. These showed me 21.12A and made 11,695.6 lumens. Better! Of course they fall like a ton of bricks, so I decided to rebuild it.

The piece of 3” pipe I used to make the bezel, initially, left very little shelf for the lens to seat against. Figured to make a new bezel and a 26650 battery tube…

So now, with a thicker walled and nearly exact external diameter 6061 pipe I was able to get a nice wide shelf for the lens and put an o-ring groove into the face of the shelf. So the lens is sealed up top. This is an UCLp lens from flashlightlens.com

You can make out the o-ring at the lens in this side angle shot. The bevel on the bezel is the same angle I used everywhere there was a bevel, this is the angle the reflector required to mate up in the head.

In this next shot you can see how I sleeved the bezel to allow a difference in lens thickness, the UCLp is 2.25mm thick but a lot of good glass out there is 3mm or more, so I allowed for a few mm of play in case I wanted to change lenses later.

The 3 XHP-50.2’s in the KaiDomain reflector

The overall modified light with it’s 26650 battery tube… I’m not good at knurling. I know there are diameters that work well with a given tool and there are diameters that do not. For the first time I tried using the feed on the lathe and started the knurling tool at a fairly deep set. This resulted in a tight spiral groove with the opposing steps stacked and killing the diamond pattern. It feels good in hand, doesn’t look bad unless you look really close, but it is what it is…

Since I had already done a lot of work on the tail cap with the smaller tube and had some copper invested in it, I decided to salvage the switch mechanism and copper of that previous version. To do this, I simply cut threads right into the knurled tube! Using it as a plug to thread into the larger tube and cutting a matching ramp in the opening of the bigger tube allowed it to work. Makeshift, perhaps, but it works. Silly



So now it takes 26650 cells, waiting on some new LiitoKala 5000mAh 26650’s to arrive from GearBest.

Initial look at a pair of Basen’s shows me 11,247 lumens. Still in the ball park with more capacity.

Hope to get some beamshots tonight but it’s been raining so it might be later in the weekend.

Thanks for cheking it out! Lot of work in building a light, probably have 20 hours in this what with a couple of screw-ups on my part. And so the learning curve continues…

Edit: Beamshots added 3-26-17

This is from the same ol Canon G1X camera, 4 times faster shutter… ISO 1600 at F/5.8 with 1/8 second shutter in Manual mode on the tripod. First is 28mm equivalent, second is 112mm equivalent or 4X.

The red 55gal oil drum is at 97 yds, spring is fully upon us so everything’s getting bushy! lol

Dale

Edited by: DB Custom on 03/26/2017 - 21:58
djozz
djozz's picture
Offline
Last seen: 1 hour 11 min ago
Joined: 09/07/2012 - 17:04
Posts: 10046
Location: Amsterdam

Great build! It takes a Dale to be not completely happy with 11K lumen! Big Smile

I’m looking forward to the Liitokala cell results!

CRX
CRX's picture
Offline
Last seen: 42 min 32 sec ago
Joined: 04/02/2013 - 15:27
Posts: 1743
Location: Scotland

Looks nice Thumbs Up

DB Custom
DB Custom's picture
Offline
Last seen: 5 hours 5 min ago
Joined: 01/13/2013 - 22:28
Posts: 14969
Location: Heart of Texas

Crazy isn’t it? I had no real idea what 3 of those emitters would be capable of, but had it in mind they should easily do 15,000 if not 20,000 lumens. So, well you know, you put in the time and you want RESULTS! lol

They could gobble up 30A, sure they could, but finding the pair of cells to give it to them is another matter altogether.

Dale

DB Custom
DB Custom's picture
Offline
Last seen: 5 hours 5 min ago
Joined: 01/13/2013 - 22:28
Posts: 14969
Location: Heart of Texas

Oh, by the way, it weighs 2.61 lbs (1184 grams) with 2 Efest purple 3500mAh 26650’s inside. Wink

Dale

MRsDNF
MRsDNF's picture
Offline
Last seen: 1 hour 40 min ago
Joined: 12/22/2011 - 21:18
Posts: 10925
Location: A light beam away from the missus in the land of Aus.

Thanks for the build thread Dale. Your light is a real winner and looks amazing. Keep up the excellent (machining) work. Smile

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.

 

EasyB
Offline
Last seen: 2 hours 30 min ago
Joined: 03/09/2016 - 15:24
Posts: 1041
Location: Ohio

Very nice. I like the look of the head.

DB Custom
DB Custom's picture
Offline
Last seen: 5 hours 5 min ago
Joined: 01/13/2013 - 22:28
Posts: 14969
Location: Heart of Texas

I wish I could knurl em like you do my friend, maybe some day…

Dale

mattlward
mattlward's picture
Offline
Last seen: 1 hour 44 min ago
Joined: 06/19/2015 - 09:20
Posts: 2059
Location: Illinois, USA

Wow Dale, that looks great… God I really want a lathe, going to look at an Atlas Heavy 10 with collets, good adjustable 3 and 4 jaw heads and a multi-tool holder this weekend. The fella also has a very clean Bridgeport knee mill with DRO and all are set up for single phase operation.

EDC rotation:
Convoy S2+, 6*7135, XM-L2 3D, 10 degree TIR, PilotDog lighted tailcap.
Convoy S2+, H17F, XM-L2 4C, lighted tailcap
Zebralight SC52w-L2
Olight S1A
Olight S1R

ToyKeeper
ToyKeeper's picture
Offline
Last seen: 4 hours 22 min ago
Joined: 01/12/2013 - 14:40
Posts: 5355
Location: (469219) 2016 HO3

These look like they’d power that light nicely:
http://budgetlightforum.com/node/53534
HKJ actually melted his battery holder before the cell’s amperage was maxed out!

DB Custom
DB Custom's picture
Offline
Last seen: 5 hours 5 min ago
Joined: 01/13/2013 - 22:28
Posts: 14969
Location: Heart of Texas

So where can I find those? I wanna melt something! Big Smile

Dale

The Miller
The Miller's picture
Online
Last seen: 3 min 40 sec ago
Joined: 12/14/2015 - 12:08
Posts: 7566
Location: Charente France

Well just awesome!
so cool these really build from stock bars projects, but so far out of reach for us mere mortals Wink

DB Custom
DB Custom's picture
Offline
Last seen: 5 hours 5 min ago
Joined: 01/13/2013 - 22:28
Posts: 14969
Location: Heart of Texas

Couple of years ago I was bolting bar stock to my drill and using a rotary tool to cut out what I wanted. Now I use the 10×22 lathe in much the same manner. lol
All Professionals are trained amateurs. Everybody starts somewhere, me? I just have to keep starting with my horrid memory…

I make my share of mistakes, like when I was making this simple spacer with one step to go between the retaining ring and pcb of the switch… in that last split second when you expect the part to fall in your hand it does the unexpected and flips over, jamming the lathe to a complete stop and mangling the last 30 minutes of careful work. And so it goes…

Dale

mattjk
mattjk's picture
Offline
Last seen: 3 days 15 hours ago
Joined: 05/22/2016 - 18:51
Posts: 158
Location: United Kingdom

Looks sweet pal! More like a piece of art than a torch.

Shame you cant buy many unorthodox designs (i’d love to turn one but i don’t have access to the equipment)

Tom E
Tom E's picture
Offline
Last seen: 8 hours 8 min ago
Joined: 08/19/2012 - 08:23
Posts: 9787
Location: LI NY

Gorgeous job once again Dale!! You need those SAM 21700's. Can you make be a 3Px2S 21700 battery tube for my 16X? smile

blueb8llz
Offline
Last seen: 10 hours 55 min ago
Joined: 06/02/2012 - 01:16
Posts: 2600
Location: California

Wow this has to be my fav of all your scratch builds. The looks is just awesome. You really gone a long ways, I can totally see the improvements in design and total build.
Keep up the great work!

THE_dAY
Offline
Last seen: 2 hours 37 min ago
Joined: 05/18/2013 - 12:56
Posts: 436
Location: sfv, california
Ahh beautiful, making me really want one of your customs!
DB Custom
DB Custom's picture
Offline
Last seen: 5 hours 5 min ago
Joined: 01/13/2013 - 22:28
Posts: 14969
Location: Heart of Texas

Tom, that’s something I have yet to learn. Offset turning. I have the 6” 4 jaw chuck and the offset plate but don’t know how to set it all up. Figured I’d get there one of these days but haven’t so far. Maybe MRsDNF will take another vacay and swing by and show me how all that works. Wink I could of course run up to North-West Texas and get Dan to walk me through all that.

Dale

MRsDNF
MRsDNF's picture
Offline
Last seen: 1 hour 40 min ago
Joined: 12/22/2011 - 21:18
Posts: 10925
Location: A light beam away from the missus in the land of Aus.

Its not as hard using a four jaw chuck as it seems Dale. Some marking out and a centre pop where the centre of the hole is. With a centre in the tailstock run it up to the work piece and adjust the jaws until your centre pop mark is central to the centre in the tailstock.

We have all watched what you can do dale and I have 100% faith in your abilities to be able to do this. You are a natural. Thumbs Up

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.

 

TexasLumens
TexasLumens's picture
Offline
Last seen: 2 days 14 hours ago
Joined: 09/25/2012 - 23:29
Posts: 1085
Location: Amarillo, Texas U.S.A.

Super nice work Dale!! Thanks for sharing the build. TL

Texas Lumens Website… http://www.texaslumens.com

WE LIVE IN THE LAND OF THE FREE ONLY BECAUSE OF THE BRAVE!

ImA4Wheelr
ImA4Wheelr's picture
Offline
Last seen: 11 hours 30 min ago
Joined: 02/03/2013 - 14:51
Posts: 7323
Location: SC

So much amazing goodness going on in this build.

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

- George Foreman 2017

staticx57
Offline
Last seen: 1 day 10 hours ago
Joined: 04/11/2016 - 00:43
Posts: 324
Location: New Jersey, United States

Wow, this is amazing!

Rufusbduck
Rufusbduck's picture
Offline
Last seen: 2 days 10 hours ago
Joined: 04/04/2012 - 15:34
Posts: 10352
Location: Golden state

Wow, if you hit 12 A it will only be briefly as the cells drop to 3.6V almost immediately. Facepalm silly me, might get more than an hour at 12 A.

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

Scott

ven
ven's picture
Offline
Last seen: 2 hours 4 min ago
Joined: 09/09/2016 - 11:39
Posts: 240
Location: Manchester

The talent on BLF never ceases to amaze me , amazing stuff……………wow

Caleb
Caleb's picture
Offline
Last seen: 6 hours 11 min ago
Joined: 03/13/2016 - 01:28
Posts: 277

Wow!! Truly impressive!!

texas shooter
Offline
Last seen: 32 min 26 sec ago
Joined: 08/26/2012 - 02:14
Posts: 953
Location: Texas

Dale how do you keep the switch from liquidizing? Not that your madness needs coaching. You still have that Trustfire TR-J20? Think triple 20700 stacked 4 high, 3×4. Twelve XHP50.2 42000 lumen. Just idle thinking.

Nicolicous
Nicolicous's picture
Offline
Last seen: 15 hours 21 min ago
Joined: 04/16/2016 - 08:28
Posts: 559
Location: Australia

nice.

you making some for sale Dale?

pinkpanda3310
pinkpanda3310's picture
Offline
Last seen: 1 day 16 hours ago
Joined: 12/28/2013 - 08:45
Posts: 1206
Location: Perth

Fantastic work Dale. I’m a little jealous as my lathe is in the middle of upgrades. I bought a bicycle sprocket to use as an indexing plate but the centre hole is not quite as centre as I’d like. So I need to fit a 4 jaw chuck to hold it and work it a bit, that in turn requires the backplate to be machined to fit. I keep thinking to myself this would be much easier if everything was already set up on the lathe FacepalmFacepalm

Anyway love your light Thumbs Up

JasonWW
JasonWW's picture
Offline
Last seen: 27 min 42 sec ago
Joined: 10/22/2016 - 11:41
Posts: 1098
Location: Houston Texas

Thats very nice work.
Did you build it as something in between a flooder and a thrower? Like a general purpose light?

I’m thinking all that copper would be good for some xhp70’s, but you probably already have a triple xhp70, right? Lol

My Convoy L6 thread with Texas Avenger FET driver, Narsil ramping firmware, lighted side switch and cut down SMO reflector. Lots of amp draws on stock driver as well.

http://budgetlightforum.com/node/54477

DavidEF
DavidEF's picture
Offline
Last seen: 8 hours 45 min ago
Joined: 06/05/2014 - 06:00
Posts: 4613
Location: Salisbury, North Carolina, USA

ToyKeeper wrote:
These look like they’d power that light nicely:
http://budgetlightforum.com/node/53534
HKJ actually melted his battery holder before the cell’s amperage was maxed out!

Yeah, when Dale said the 20700’s weren’t performing like he thought they should, so he made it a 26650 light, I immediately thought of this review, where HKJ said these 21700’s outperform a 26650 for high amps. Dale, you were so close. You already said your first tube could fit the 21700’s. Now, you’ve got a regression it seems! Well, at least 21700’s will fit in the 26650 tube using a sleeve, as long as you made the tube long enough. You did make it long enough, right?

Reason is not automatic. Those who deny it cannot be conquered by it. Do not count on them. Leave them alone.
-Ayn Rand

DB Custom
DB Custom's picture
Offline
Last seen: 5 hours 5 min ago
Joined: 01/13/2013 - 22:28
Posts: 14969
Location: Heart of Texas

Scott, it does 12A in a lower mode… Turbo is around 20A.

I’m actually using a mini Omten, the spring is bypassed but it’s not a through board bypass which I should probably do and that might get me a wee bit more.

My TR-J20 has a massive heat sink in it and has 4 of the 9V MT-G2 on it, making 15,000 lumens as well. Of course, I could acquire another… Wink (This heat sink is what let RMM’s TR-J20 with 12 XHP-50’s work at 39,000 lumens, I’ve got an additional 1/4” thick plate up top. RMM’s had an extension tube I made to carry a 4th 32650 cell. Pretty sure Slow2Go has RMM’s TR-J20 now.)

I didn’t know if it would be more flood than throw or what to expect. This is a new reflector to me and of course the emitters are brand new as well. That said, the hot spot is quite surprising and it manages to show black on dark green in the absolute dark of night (no moon) to 225 yds or so which is sufficient. I looked at the red oil drum from about 75 yds last night and the overall results are very satisfying. Had been rainy, was threatening and lightning abounded so I didn’t set up the tripod for beamshots. I did have a triple XHP-70 in an BTU Shocker. I had to tame the donut hole with large TIR’s in each reflector cup but it worked out really nicely and made 11,000 lumens on a pair of 18650’s and 14,448 lumens on 6 18350’s. I had modified a carrier to take the small cells, had both carriers. This light also hit 20,000 lumens with 3 18650’s for a very brief test. Copper traces on the carries vaporized, I repaired the damage with fairly heavy copper plate but never tried 3 cells again. I sold that one having also a Shocker with 3 of the 9V MT-G2’s at ~10,000 lumens that I’m very fond of.

And yes, I built it originally for the 21700 cell that wasn’t available and still isn’t available. Then I realized that while this cell might be wonderful and all that it’s still only a 3000mAh cell and even IF it could deliver 30A then it’s only about 6 minutes worth at a 10C discharge. While that hasn’t stopped me before, the 26650 tube can easily take the smaller cell. And yes, it’s long enough. I have put Molli 26700’s in it. They just kinda suck.

PinkPanda, get that thing back together and get busy man! Big Smile

Thanks guys, appreciate it. For me, still new to the lathe, it is quite a labor of love to get something like this done. I still have a couple of tweaks to go to enable the o-rings to fit and have it in finished shape but those should be minor. (hopefully not famous last words) You can see a shiny silver ring where the battery tube meets the copper, this is because it’s not seating that last couple of mm due to me not being able to cut the threads all the way to the bottom of the driver bay. I need to either cut a relief down inside that copper or remove a couple of threads from the end of the tube. Similarly, where the bezel slips over the head in an almost press fit I need to continue that “landing” for the o-ring up there to be able to fit in. Essentially simple, with plenty of room for major catastrophic failure. lol

Dale

Pages