4x XPL HI SRK, C8 Reflectors

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Kourtinoksylo
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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.

-SkyRay King 4x XPL HI, TN40 copy http://budgetlightforum.com/node/55195
-XHP70.2 Maglite 2D http://budgetlightforum.com/node/54791
-SkyRay King 7x XML2, TIR, 8x 18650 http://budgetlightforum.com/node/54886
-Coming next: 4x XHP50.2 air-cooled...

Edited by: Kourtinoksylo on 07/08/2017 - 04:56
zeremefico
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Jetbeam T6?
Nice work.

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Kourtinoksylo
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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.

-SkyRay King 4x XPL HI, TN40 copy http://budgetlightforum.com/node/55195
-XHP70.2 Maglite 2D http://budgetlightforum.com/node/54791
-SkyRay King 7x XML2, TIR, 8x 18650 http://budgetlightforum.com/node/54886
-Coming next: 4x XHP50.2 air-cooled...

djozz
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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.

Ozythemandias
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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?

giorgoskok
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Very nice work !

Many times better than a TN40 , now that you made it from scratch Big Smile

Kourtinoksylo
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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…

-SkyRay King 4x XPL HI, TN40 copy http://budgetlightforum.com/node/55195
-XHP70.2 Maglite 2D http://budgetlightforum.com/node/54791
-SkyRay King 7x XML2, TIR, 8x 18650 http://budgetlightforum.com/node/54886
-Coming next: 4x XHP50.2 air-cooled...

scotlarock
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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.

EasyB
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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?

DBSAR
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awesome work on this Big Smile

That Canadian flashlight guy & Lantern Guru -Den / DBSARlight

Box
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That’s amazing. Awesome job mate. The light looks professionally done Thumbs Up

Kourtinoksylo
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EasyB wrote:
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?

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 Big Smile

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

-SkyRay King 4x XPL HI, TN40 copy http://budgetlightforum.com/node/55195
-XHP70.2 Maglite 2D http://budgetlightforum.com/node/54791
-SkyRay King 7x XML2, TIR, 8x 18650 http://budgetlightforum.com/node/54886
-Coming next: 4x XHP50.2 air-cooled...

EasyB
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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.

Kourtinoksylo
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scotlarock wrote:
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.

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!!!

-SkyRay King 4x XPL HI, TN40 copy http://budgetlightforum.com/node/55195
-XHP70.2 Maglite 2D http://budgetlightforum.com/node/54791
-SkyRay King 7x XML2, TIR, 8x 18650 http://budgetlightforum.com/node/54886
-Coming next: 4x XHP50.2 air-cooled...

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

Reason is not automatic. Those who deny it cannot be conquered by it. Do not count on them. Leave them alone.
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Kourtinoksylo
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DavidEF wrote:
Nice build! It reminds me of this one from Old-Lumens a while back. His is a little teensy tiny bit bigger though! Big Smile

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

-SkyRay King 4x XPL HI, TN40 copy http://budgetlightforum.com/node/55195
-XHP70.2 Maglite 2D http://budgetlightforum.com/node/54791
-SkyRay King 7x XML2, TIR, 8x 18650 http://budgetlightforum.com/node/54886
-Coming next: 4x XHP50.2 air-cooled...

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

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

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

CRX
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Nice Thumbs Up

ImA4Wheelr
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Wowser!  That's some nice work there Kourtinoksylo.  Congrats!

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ImA4Wheelr wrote:

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


I’m with ImA4Wheelr and others with their comments. This is a really nice mod. The reflectors look amazing and I admire your skills in building this wonderful light. Thanks for posting it up.
One thing, next time dont be shy in posting up lots more pictures in the fabrication process. Smile
Long live Justin. Thumbs Up

My current and or voltage measurements are only relevent to anything that I measure.

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Old-Lumens. Highly admired and cherished member of Budget Light Forum. 11.5.2011 - 20.12.16. RIP.

 

FmC
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Very nice outcome Beer

Interested to see the output on better cells Thumbs Up

Jerommel
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Awesome job on the reflector(s). Thumbs UpThumbs UpThumbs Up

Looking for:

5” parabolic reflector (for recoil light)

Mr.Scott
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No pictures. Sad

Just Photobucket’s “Please update your account to enable 3rd party hosting”

will34
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Great reflector job! looks very clean.

Kourtinoksylo
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I fixed the issue with the pictures, thanks to everyone for the comments!

-SkyRay King 4x XPL HI, TN40 copy http://budgetlightforum.com/node/55195
-XHP70.2 Maglite 2D http://budgetlightforum.com/node/54791
-SkyRay King 7x XML2, TIR, 8x 18650 http://budgetlightforum.com/node/54886
-Coming next: 4x XHP50.2 air-cooled...

glide 1
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Great build! The C8 reflectors turned out very clean when glued. Congrats!

Mike C
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Nice build! It’s the first time I’ve heard of plexiglass as lens. Any particular kind of plexiglass? Or did you just use “normal” stuff that anyone can get anywhere?

Kourtinoksylo
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Mike C wrote:
Nice build! It’s the first time I’ve heard of plexiglass as lens. Any particular kind of plexiglass? Or did you just use “normal” stuff that anyone can get anywhere?

Yes normal Plexiglas/Acrylic from eBay, not optic grade not AR coated just plain PMMA. I was not satisfied with the performance of AR glass from the popular websites so I tried this solution. I bought a 40cmx40cm piece, 2mm thick and I cut it in any diameter I want for any flashlight. Cost 10euros for this size.

I just did some measurments with a flashlight that I have, its output in mid mode is:
1.Without lens:……………1640lm 100%
2.Plastic Maglite lens:….1550lm 94.5%
3.AR Coated 2mm:………1525lm 93%
4.Plexiglas:…………………1592lm 97%

Even if my measurment method is false in terms of lumens, we are interested here about relative changes between different types of glass. I tested the lenses back and forth 2 times, always same results with difference of 6-10lumens, probably because of battery drain.

So I see absolutely no reason to pay 2 or 3 dollars a piece for AR coated glass and wait weeks for it to arrive. I just cut it in a matter of minutes any size I want and on top of that its better in terms of performance… As a downside I could imagine that it gets easily scratched, but you cut a new one when needed…

-SkyRay King 4x XPL HI, TN40 copy http://budgetlightforum.com/node/55195
-XHP70.2 Maglite 2D http://budgetlightforum.com/node/54791
-SkyRay King 7x XML2, TIR, 8x 18650 http://budgetlightforum.com/node/54886
-Coming next: 4x XHP50.2 air-cooled...

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I’m not questioning your numbers, but something seems amiss when a Maglite lens and/or a hand-cut piece of Plexiglas can out-perform the AR coated lens. Flat Stare

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

Kourtinoksylo
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The measurment is correct, I dont know however about the quality of the AR glass. Mine is 52.6mm-1.6mm from KD, described as multi AR coated. I didnt find the size in any other shop to test it. Anyway even if proper AR glass is outperforming Plexiglas it would be for 1%, for me it isnt worth the cost and wait.

What would be the light transmission rate of a good AR coates glass?

-SkyRay King 4x XPL HI, TN40 copy http://budgetlightforum.com/node/55195
-XHP70.2 Maglite 2D http://budgetlightforum.com/node/54791
-SkyRay King 7x XML2, TIR, 8x 18650 http://budgetlightforum.com/node/54886
-Coming next: 4x XHP50.2 air-cooled...

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