Scratch-built 7x C8 reflector high-output thrower

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EasyB
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Scratch-built 7x C8 reflector high-output thrower

With this light I wanted a big powerful thrower. Available hosts didn’t provide exactly what I wanted so I started playing around with some design ideas. 7 C8 reflectors fit nicely in a 5” circle, so I looked through online metal shops to find suitable material and with the help of machine shop access I put the light together.

It has 7 dedomed XPL V6 1A emitters powered by 2×26650 cells in series. The emitters are in 4p-3p configuration. The electrical setup is the same as my 7xXPL convoy L2 mod. It pulls right around 15A on fresh Liitokala 26650s. It does around 8800 lumens at 15sec and 739Kcd at 30sec (measured at 10m). The beam is practically the same as a C8 with dedomed XPL.

Here are the parts layed out. The emitters sit on a 1/4” thick 5” diameter Al plate. The reflectors are housed by a 5” OD Al tube with 1/8” wall thickness. I made a flange which bolts to the bottom of the plate and has a threaded connection for the battery tube.

Here is the flange being made on a lathe. I made the internal threads on the flange and tailcap with a tap (1 1/4”-12) and cut the external threads on battery tube using the thread-cutting function on the lathe.

Here I’m test fitting the reflectors in housing. The reflectors had to be shaped a bit in order to fit in the available space. I did this by hand with a file so the angles aren’t perfect. The top of the housing has six threaded holes which allows the lens to be tightened down on the reflectors.

Copper disks in the flange and tailcap make contact with the battery tube. In the tailcap the copper disk is electrically isolated from the Al tailcap itself so I can lock out the light by unscrewing the cap by a turn. These connections are sealed with orings on the battery tube.

The copper disk in the head rests against a small hollow spacer (I used a 26650-18650 converter). The 17mm driver ground ring is soldered to the copper disk. The driver itself is an old mtn FET driver I had. It’s hard to see in the picture, but I piggybacked a small 5V regulator to power the MCU in order to get low stand-by current. Capacitors in the “C1” and “Zener cap” spots on the driver board serve as input and output capacitors, respectively, for the regulator, as recommended in the datasheet. I have ToyKeeper’s e-switch ramping FW flashed on the attiny13.

I attached the housing to the head plate using JB weld.

The e-switch is a small unit I bought from radioshack. It is covered with silicone (RTV gasket maker). It doesn’t look pretty, but it works to protect and waterproof the switch. There are 6 28mmx28mmx20mm heatsinks attached to the back of the emitter plate. I haven’t done any extended on-time heat testing, but I think the heat-handling should be relatively good. The heat spreads from the plate to the housing well, and the thermal path from emitters to heatsink is almost ideal in this configuration.

Here it is compared to a convoy L2 and C8. It is fairly compact height-wise, but of course the head is very large. As it is now it weighs 980g with 2 LK 26650s.

Here is the view from the front. The lens is UCLp from flashlightlens.com. A problem I didn’t anticipate was caused by the flexing of this plastic lens. When the bezel is tightened the lens bows up slightly in the middle and doesn’t press down equally on all reflectors. I put some spacers on the center reflector to mitigate the problem, but it is not ideal. I need a stiffer lens. I plan to seal up the front parts by making gaskets out of suitable rubber sheet material.

This light really deserves some long-range beamshots, but I don’t know when I’ll get those. Thanks for looking!

Edit: Beamshots added in post 35.

Edit: emitter upgrade post 61

Edited by: EasyB on 09/19/2018 - 22:59
MRsDNF
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You are a nutter EasyB. A good one at that. This brings back memories of a past member here that is gone but not forgotten. I love every bit of your build with your creativity and skills you have made a wonderfully unique light. Well done. SmileThumbs 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. 

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CRX
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A nice monster Thumbs Up

everydaysurvivalgear
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Wow crazy built mate. Good work!

kennybobby
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That is awesome.

Litefighter
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That’s one heck of a build! Looking forward to those beamshots. Thumbs Up

Does it have a name yet? Mjölnir seems fitting.

NeutralFan
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That is one mean looking cool flashlight! Good job on centering the LEDs too. Looking forward to some beam shots.

I’d rather use my flashlight around the house than turn on the lights.

EasyB
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Thanks for the comments, guys. I will look for a good location to do the beam shots. I’m thinking about 300-500m is a good distance to show the strengths of this light.

pinkpanda3310
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Wow, awesome build Thumbs Up

You might think about making a second one for body symmetry LOL

Looking forward to the beamshots Cool

KawiBoy1428
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Awesome! Beer

KB1428 “Live Life WOT”

WillyD
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Wow! 9,000 lumens with a mile of throw! Awesome job!

blueb8llz
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Insane! Never would have thought u could get close to 800kcd with c8 reflectors.
I would have guessed 350kcd.

Rufusbduck
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Maybe not with one but with 7 all well aimed maybe so.

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

Scott

gastonpatagonico
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Excellent!!!! We want photos in operation !!
SteveMidwest
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Thanks for sharing this with us EasyB! Thumbs Up

Flashlights are so much fun to build. I really look forward to the beam shots, and a possible YouTube video of this Beast.

Well done. You are now King Crown of the C8 combo!

Enderman
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blueb8llz wrote:
Insane! Never would have thought u could get close to 800kcd with c8 reflectors.
I would have guessed 350kcd.

Well, candela scales almost linearly with the number of heads you add to the light…
If one head can do >100kcd then 7 heads will do >700kcd.
Angler
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Holy smokes! Nicely done!

Maybe you should call it “C56” Big Smile

southland
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Sweet.

The Miller
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Wow what a monster!

FmC
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That’s pretty cool Beer

Beamshots!!!!

DavidEF
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Nice build! Like others, I’m looking forward to the beamshots!

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ImA4Wheelr
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Love it.  Congrats on the monster.

giorgoskok
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So cool ! A real monster Wink

You should check output with some 30A batteries , some VTC5 / VTC5A or newer 20700 40 amp batteries .

EasyB
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Glad you guys like it. Smile

As some have pointed out, this light is essentially 7 C8s pointed at the same spot. On average that is 105Kcd per reflector. Better driven (6A per LED), this light could reach 7*150Kcd=1050Kcd. Right now 3 of the LEDs are getting 5A and the other 4 are getting 3.75A. I could rewire the LEDs to work with 3s (2p-2p-3p). I estimate that this would increase output and throw by 12%, but increase power consumption by 25%.

I’ve got a couple 3-500m beamshot locations scoped out on google maps..

bibihang
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Very interesting build! If you use XP-L HI emitters I think the candela can easily break the 1M mark!

Slayer1
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Insane monster build!! Thumbs Up

EasyB
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bibihang wrote:
Very interesting build! If you use XP-L HI emitters I think the candela can easily break the 1M mark!

These are dedomed XPL V6, so already higher luminance than available XPL HI bins.

Speed4goal
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Wow amazing work, who needs a tn42 when you can have this

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Speed4goal
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bibihang wrote:
Very interesting build! If you use XP-L HI emitters I think the candela can easily break the 1M mark!

Xpl hi only goes up to V3 bin. Xpl v6 throws more when dedomed.

Xpl hi is nice for choosing what tint you prefer and not having to dedome emitters

2/9 Fox Co (2009-2015) Semper Fi 0311/0331 Rifleman/Machine Gunner
Blf has changed a lot since I've been here. Lots of snow flakes and easily offended over nothing. When the forum use to be great and people joked around and could take a joke. It's a forum it's not that serious. Let's make BLF great again!

Sprinkles
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Yeah, but does it tailstand? Silly

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My god man, get a grip on it! That is one cool build!

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

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