4x XPL HI SRK, C8 Reflectors

This is my 3rd mod, a cheap TN40 copy using a SkyRay King as host. Reflector design inpired from OldLumens!

Parts:
–4x C8 Reflectors
–4x XPL HIs on SinkPads
–77mm lens hood
–82mm lens filter with 2mm thick Plexiglass lens(meassured 2-3% better light transmission than AR coated class!)
-Stock driver, added an addiotional mosfet and thicker wiring
-As heatsink I cut 2mm Alu discs and screwed them together
-Bridged the tail springs

Here some pictures:

In the first picture it seems that the led reflections are not covering the whole reflector, in reality I must go very far from the light (5-6m) to have full coverage in the reflectors, the beam is so narrow that from a near distance only the center of the reflectors are showing. Foto is taken at 3meters.

The reflector was the big challenge of this project as misaligment or differences in angle would reduce the throw and the quality of the beam. I tried my best and from what I see I am pleased with the result.




-The output reaches 4500lm on 100, and around 1400lm on low(around 30), the stock driver has only those two modes but is ok for me. The flashlight is running really cool because of the big size, big heatsink and the relatively low current on the emitters. On low mode it never becomes warm, in high mode the head starts to be warm to the touch after 4-5min of operation.
–4500lm from 4 leds is pretty conservative. I was aiming for something around 5500-6000lm but somewhere in the circuit I have a weak spot and I cant find it… Wires from the driver are 16awg and to the leds 20awg, which I think should be enough for 6000lm=20amps more or less…. Springs are bridged, double mosfets, bridged current limiting resistors, batteries are 3400mah Panasonic. No idea what is holding this flashlight back….
-Unfortunately I dont have a beamshot yet, I also promised beamshot for my Maglite but I didnt find a nice place to test them… I will do it in the future. Some tests outside are very promising, I have lightened up tress at 500m with ease. I promise to make beamshots, give me some time!

Hope you like it, thanks for reading. Suggestions are always welcome.

Jetbeam T6?
Nice work.

Ευχαριστω, yes something like T6 or Thrunite TN40. I was hoping for more output than these two to compensate for my inferior reflector. I didnt manage to pass 4500lm however.

Very nice work, that should already throw around 400 kcd.

Yes, look further to possible resistances, the traces on XP Sinkpads are not wide but that does not explain it all. Look on the driver board for narrow bits too.

3rd mod?? I’m embarrassed! Great stuff!

How’d you do the reflectors? Seems to be cut then bonded with JB Weld, how did you know where to cut?

Very nice work !

Many times better than a TN40 , now that you made it from scratch :smiley:

I have done many small mods on flashlights, I mean this is my 3rd big one and my 3rd on the forum.

Exaclty, the refectors are epoxied together with smth like JB weld.
I made lots of templates from paper to see exaclty how much I needed to cut. At the end I just cut as much as needed to not have a hole in the center of the reflectors. Theoretically if you have a bigger head you can avoid cutting or you can cut only 2-3mm from each, you will end up with a hole in the center however…

Very cool light! My guess as to what is holding back the output, the cells. You stated they are 3400 mph panasonic, assuming they are 18650 “B” then they won’t flow the kind of current you need for more lumens.

Awesome mod! I’m a fan of high-output throwers and this one looks real nice. The reflectors look very cleanly cut. How did you cut them?

Are there SRK hosts with that big of a head? Or how much of the host did you custom-make?

awesome work on this :smiley:

That’s amazing. Awesome job mate. The light looks professionally done :+1:

After I found out with paper samples the best shape, I cut a metal template and used this for all 4 reflectors to make them all even.
I started cutting with a small saw, then squared them with a small disc sander that I have.

Skyrays are only one size of what I know, the big head is a camera lens hood and some aluminum discs.
The original body ends around 12mm from the switch. You can tell where the extra parts start from the glossy color, I didnt have matt black spray :smiley:

Here is the template, I was cutting the part of the reflector that was outside of this shape!

Oh, so you used Al disks of alternating diameter to create the fins. It looks really clean.

As someone above mentioned, if you are using the NCR18650B cells, these will significantly limit your output as they have pretty high internal resistance.

You are right! I thought these batteries are capable for what I wanted, but I tried some 10amp LG cells and the lumens are indeed going up… Thanks for the advice!

And thanks to everyone for the kind words!!!

Nice build! It reminds me of this one from Old-Lumens a while back. His is a little teensy tiny bit bigger though! :smiley:

You are right, I was inspired from his project, I will write it in my original post! It needs to be mentioned….

very nice
those reflectors, ehm that quad reflector looks very good!

That’s some heavy duty modding Kourtinoksylo! Looks very nice and looking forward to some beamshots.

Nice :+1:

Wowser! That's some nice work there Kourtinoksylo. Congrats!