CRX Stratis Lumina - 2017 5th BLF Scratch Made Light Contest Entry

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CRX
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CRX Stratis Lumina - 2017 5th BLF Scratch Made Light Contest Entry

Hello and welcome to my build thread for the 2017 5th Annual BLF / Old Lumens Scratch Made Light Contest which is a competition where BLF members take part by making a flashlight or set thereof from scratch and was started by now deceased member Old Lumens who loved modding and making flashlights.

There are two categories, Machine made and Hand made.

Again I will be entering the hand made category and making the light(s) using only small hand held tools.

This years flashlight will be made from copper and wood, C101 1.2mm copper sheet and Indian rosewood.

I have never worked with wood before so this should be an interesting experience.

The format for the light will be similar in nature to one of my previous Monolith builds except better Wink 

Incorporating alternating stratis of copper & wood and be similar in size to a credit card although a lot thicker.

I have some stuff here but have ordered special materials for the body of the light and waiting for them to arrive, some members have no patience  Big Smile so I have made some images up with the concept I am planning.

The light will be a quad emitter setup for the main lumina powered by a 17mm 105c 3A Nanjg driver and also have auxiliary red and UV emitters operated by a secondary momentary switch or mercury tilt switch so depending on how the light is positioned these will be on or off, see an example of mine here

The main driver will be a Nanjg 105c 3Amp with MoppyDrv firmware and operated via a blue tritium momentary switch on top.

The light will be powered by a 1200mAh lithium polymer cell with a charger board built in and wired to a micro USB port.

.

CRX Stratis Lumina Finished

This light has three modes of operation, a tritium momentary locator switch on top for operating the main quad Nichia emitters via the Qlite 3A driver giving a sustained maximum of around 1092lm, a glow in the dark momentary switch for operating the eight UV front emitters and a mercury tilt switch which automatically turns on the four bottom red LED's when the light is placed faced down or thereabouts.

Features:

Quad Nichia 219C D320 5000K Emitters

MTN 20mm Offset Quad DTP MCPCB

10621 Carclo Quad Spot Optic

34mm x 2mm Dual Coated ARC Glass

QLITE Momentary 3A Driver with Moppydrv

Dual Momentary & Mercury Tilt Switches

Ice Blue Tritium Locator Switch

Cyan Coloured Glow Details

1200 mAh Lithium Polymer Cell

TP4056 Micro USB On Board Charging

8 x 3mm 400nm UV LED's

4 x 3mm Deep Red LED's

CRX Etched Lettering

Copper & Rosewood Construction

Hand Made Leather Carry Case with Clip

Length - 86mm

Width - 52mm

Depth - 22mm

Weight - 250g

Max - 1092 lm

Time Taken - Approx 40 hours

.

CRX SL Mini

This complementary light is much smaller in size for a more convenient carry and has two modes of operation with two momentary GITD locator switches on top, one for the front triple XP-G2 3D emitters giving a max output of about 392lm and one for the dual red LED's on the bottom of the light.

Features:

Triple Cree XP-G2 S4 3D Emitters

Noctigon 20mm DTP MCPCB

Mule

22mm x 1.2mm Dual Coated ARC Glass

Dual Momentary Switches

200 mAh Lithium Polymer Cell

TP5000 Micro USB On Board Charging

2 x 3mm Deep Red LED's

Cyan Coloured Glow Details

Copper & Rosewood Construction

Length - 59mm

Width - 38mm

Depth - 12mm

Weight - 75g

Max - 392 lm

Time Taken - Approx 7 hours

.

CRX SL Micro

The SL Micro is a fun light that can be worn on a neck chain for brief illumination periods and has a single mode of operation via a brass twist bolt on top which switches on the three front XP-G2 2B emitters for a maximum output of around 360lm and comes with a kydex carry clip & chain.

Features:

Triple Cree XP-G2 S4 2B Emitters

Noctigon 20mm DTP MCPCB

Mule

20mm x 1.2mm Dual Coated ARC Glass

Brass Bolt Twist Switch

200 mAh Lithium Polymer Cell

TP5000 Micro USB On Board Charging

Copper & Rosewood Construction

Hand Made Kydex Carry Sheath

Length - 40mm

Width - 25mm

Depth - 12mm

Weight - 34g

Max - 360 lm

Time Taken - Approx 6 hours

.

CRX Stratis Lumina flashlight set

Total Time Including Documentation - Approx 70 hours

.

Well here it is, going from my imagination to reality this has been a fun, educational and sometimes very difficult build but also a great learning experience.

Thank you to everyone that watched, commented in the thread and sent personal messages, I really appreciate that Beer 

Some personal observations:

The CRX Stratis Lumina turned out fairly close to the original drawings I made up with the concept of having a front elevation the size of a credit card and I am happy with the outcome.

The light performs very well, to my expectations with one of my favorite Nichia tints and the automatic red LED's for quick close range illumination when the use of the main array is not necessary. The UV is also a nice feature to have here.

Running the light on full power, the large amount of flat copper heat sinks do their job very nicely with the mid layer heating first, the internal copper heat sink block saturating to finally spread to the copper back plate with the whole light eventually becoming warm Thumbs Up

Looking back there are a couple of things I would have done slightly differently using other techniques but learning on these little creative journeys is half the reason I do it.

The SL Mini can easily be slipped in a jeans side pocket and again has enough power to be useful along with the very nice 3D tint and night vision preserving red LED's.

The SL Micro is just ridiculously small and fun for a rechargeable triple emitter hand made light and can be worn on a neck chain or kept in a pocket hardly noticed.

As usual with me, this project started off as one idea then grew into a little family all cut from the same stuff.

.

.

The CRX Stratis Lumina Basic Layers Concept

This is my original idea for how the light will be made using alternating layers of copper and wood.

These images are measured, cropped and placed manually.

Going from left to right = bottom to top sequence of layer assembly.

Layers with the wood cut out.

Electrical components layout.

CRX Stratis Lumina should look something like this, all going to plan.

.

.

Building the Lights

Below are the build highlights, clicking on the images will take you to the respective post for more information.

I like listening to music (and I use that term loosely Big Smile ) when I build torches and have included some tracks in the various posts.

You don't have to play them if you don't want to Silly 

Indian Rosewood and C101 1.2mm Copper sheet arrived

 Copper cut to rough sizes

 Rosewood cut to rough sizes

 Copper sandwich

 Working on wood

 Drilling holes for LED's, switches and USB port

Copper & wood pieces layout

 GITD LED's

Drilling copper mid layer for wiring & marked out front plate

 Rough components layout

 Drilling fixing holes in the copper & wood

Experimental etching

 Soldered standoff fixings together and attached to back plate

 Started filing work on the edges to level up

 Bodywork fitted together

 Size indication

 Drilling out front plate hole for optics

UV LED array for optic surround

Brass inserts for the switches & charger indicator installed

Temporarily illuminated to show effect

Charger indicator rod

GITD switch plunger made

Tritium switch made

Charger board installed

Red LED testBrass Driver housing

Driver test

Charger & red LED test

Mercury switch test

SL Mini built

Switches, Quad and UV Array installed

 Front glass and plates fitted

 

Made a leather carry case

Etched username into copper

SL Micro is born

Kydex holder made

Stratis Lumina Set Complete

.

                                                                      

Today's Tune:

Thanks for your support... Thumbs Up

Edited by: CRX on 10/31/2017 - 17:35
LightRider
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Looks great! I like the look of the polished copper, GITD switch and blackened finns Big Smile

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Is it really, really small??

‘cause I can’t see anything… Silly

raccoon city
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Nanotechnology!

CRX
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I haven’t even started yet. Tough crowd LOL

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The bar is where you set it… Wink

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I’ll just put my glasses away then, Thanks for the update CRX. 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.

 

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CRX wrote:
I haven’t even started yet. Tough crowd LOL

giorgoskok
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Sub Big Smile

It ‘ll be good

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giorgoskok wrote:
Sub Big Smile

It ‘ll be good


Yep. Wink

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

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I knew it would be Extraordinary and Small

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Do you ever stop imagining things Question!!!
For our good, I just hope you don’t WinkBig SmileParty
Good work on this!! Thumbs Up

DB Custom said: "Hide your billfold, cut up your credit cards... you're a perfect candidate for full blown flashaholism and will soon need dedicated flashlight cabinets. [...] Have fun! Modding is next... :P" 

Reviews : Amutorch S3 - XPG3-S3 /  AM S3 vs Neal 219c  /  Amutorch AM30 - XHP70.2 / Nitefox UT20 / Sofirn SF14 & SP10A 

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Carly Simon – Anticipation

(“It’s good that most people can’t remember their previous lives. Otherwise
things would be a lot more complicated than they already are.”
Ajaan Lee Dhammadharo)

FmC
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This is looking sweet Beer

How can I get a credit card with my BLF name on it?

CRX
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Photoshop, or change your name Smile

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make sure the TIR does not get damaged by the UV

[Reviews] Miboxer C4-12, C2-4k+6k, C2, C4 / Astrolux K1, MF01, S42, K01 / BLF Q8 / Kalrus G35, XT11GT / Nitefox UT20 / Sofirn SF36, SP35 / Imalent DM21TW / Wuben I333 / Ravemen PR1200 / CL06 lantern / Xanes headlamp

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Interesting, what emitters did you have in there?
I was just planning on a low power 5mm UV emitter in the centre of the optic, probably 395nm or above as I noticed 365nm gets blocked by the plastic. I might also drill a centre hole in the optic but these decisions are made during the building.

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I would definately go to a UV 365nm Emitter like Nichia 276A which needs no filter blocking visible light

Then you need to drill a hole

For that picture someone had hard driven 365nm and thought it were 395nm ones
Likely 1.5W UV radiance per emitter

[Reviews] Miboxer C4-12, C2-4k+6k, C2, C4 / Astrolux K1, MF01, S42, K01 / BLF Q8 / Kalrus G35, XT11GT / Nitefox UT20 / Sofirn SF36, SP35 / Imalent DM21TW / Wuben I333 / Ravemen PR1200 / CL06 lantern / Xanes headlamp

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A nice wee delivery today means I can get started, a slab of copper, the rosewood and some bit's n' pieces.

The Dalbergia latifolia has a purple hue to it which is interesting, goes well with the copper I thought.

This piece is cut into a blank shape for making ukeulele/ mandolin fingerboards.

Hard as rock and sounds great too Big Smile

Today's Tune:

FmC
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DELIVERY!!

..Sorry – that’s what we yell out at work whenever the postman arrives… MailThumbs Up

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I refrained from shouting but I did smile and run to the door like an excited kid when I heard heavy stuff hitting the floor Smile

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That’s plenty of rosewood and copper to do more than one of these… Wink

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

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Looks a lot like the Eye of Sekhmet flashlight from Silent Thunder Ordnance, but smaller! Cool

https://www.silentthunderordnance.com/shop/eye-of-sekhmet

CRX
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Shame Carclo doesn’t make a 40mm catadioptric optic.

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CRX wrote:
Shame Carclo doesn’t make a 40mm catadioptric optic.

What’s wrong with the 60mm one? I’m sure with your skills, you could find a way to “fit” it to whatever you were going to use the 40mm one for. Maybe a nice “setting” like jewelers do with diamonds?

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

CRX
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I really want this light to be as compact as possible, a 40mm version would have been perfect and I don’t think filing these things down is an option Smile
Maybe could use it for a future build.
The wood I ordered is only 55mm wide but still, I’ll give it some thought Thumbs Up

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DavidEF wrote:
That’s plenty of rosewood and copper to do more than one of these… Wink
Wink
CRX
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Got the copper sheet cut into the rough shapes today.

I marked out the lines to cut with digital calipers, a set square and a #26 scalpel blade. I was not looking forward to cutting the metal with a hacksaw so I thought I would try just scoring it repeatedly with a stanley knife, about 20 times down the marked lines each side and then gently bending at the weakened points until the pieces snapped off, much easier Thumbs Up

Each layer is about 1mm larger all round than required, to be made good and sanded down later.

Reference drawing

 

I also marked out where the glass, optic and MCPCB will be situated through the front piece using the digital calipers with one point held in the centre marking and the other point used to scribe the circles around.

These circles will help to keep me right when taking out this material with a hand file.

I will cut the rosewood next.

Today's Tune:

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I love copper. How thick?

CRX
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It’s 1.2mm thick, nice stuff.

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Measured and cut the wood, now got the rough pieces made up.

Reference drawing

Looks nice but you don't want to eat this sandwich Smile

Today's Tune:

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