Air Cooled 4x XHP50.2 UPDATE: Videos, Willing to sell

48 posts / 0 new
Last post

Pages

Kourtinoksylo
Offline
Last seen: 15 hours 4 min ago
Joined: 02/25/2017 - 15:33
Posts: 78
Location: Greece/Germany
Air Cooled 4x XHP50.2 UPDATE: Videos, Willing to sell

UPDATE AT THE END OF THIS POST

I present you my latest flashlight. Its been a while sience I uploaded a mod, I hope this one will make up for it! The reflector design is inspired by Old Lumens, the heatsink and active cooling design was all my ispiration. I wanted to build an active cooled flashlight, as raw power is not everything if you cant use it more than 10 seconds. Its a little “Frankestein” looking, some will find it ugly, personally its not my favorite looking piece, however 100% innovative…


This time I have some photos of the building process too:
The host is a SRK. I used a second tube to accomodate the 8 cells.



This is the template I used to drill the holes for the heatsink. Firstly I drew it on a piece of paper and then scaled it down with a computer and printed the right size. In this way it came out more accurate and the work of drawing in bigger scale was easier.
114 holes for 114 rods, of which 64 go through all 3 copper plates.

Drilling 1mm pilot holes, and then enlargen then to 2.9mm for a tight fit with the 3mm copper rods.

The heatsink is composed of three 2mm copper disks connected with 3mm copper rods. In the middle disk I cut a 30mm hole to accomodate a 30mm fan, normally used to cool RC cars. It reaches a maximum of 23.000rpm, it moves a huge amount of air. There are videos of it on youtube. Its called WTF 30mm.


The switches and resistors are used to regulate the speed of the fan. I chose 3 speeds that thought were useful, one quiet, one middle and one almost max.

The reflectors are from KD, 36mm in diameter and were cut with a hacksaw and shaped with a file to fit together nicely. Epoxy was used to glue them together.

This is the driver I am using with Narsil firmware/ramping, 0.3mm copper sheet solderedused on the spots where the cells and carrier are contacting to prevent wear on the gold contacts. It also increased the mass of the driver, improving its heatsinking.

And some numbers…

The design of the heatsink allows a clamp meter to be connected direclty at the 13awg cable that goes to the leds. I am reading with 8 LG MJ1 3500mah cells almost 40amps, which translates to 10 per emitter and theoretically almost 20.000lumens. I suppose OTF I get 18.000lumens, maybe 17.000. The surface of the heatsink alone is calculated to 380cm^2 or 59in^2. Roughly an area 20cm x 20cm, not bad. Heat at those levels (40A and 8.4v) is still a problem but active cooling helpes immensely on middle levels.
Measurment of xhp50.2 from djozz here on this forum:

Wall shot next to a C8 with XML2. C8 on the right CW 3amps. Frankestein on the left NW around 5amps. Brighter and bigger hotspot.

Hope you like it! Comments/advice/questions always welcome!

UPDATE……………..UPDATE………………UPDATE…………….UPDATE…………….UPDATE………………….UPDATE……………

Beam shot location:

Beam shot video of my flashlights:

Active cooling demonstration:

For further information please check the video descriptions.

Some numbers:
From 23C to 52C in turbo 41sec without fan. With fan 50sec. Ambient temp 23C. (indoors)
From 7C to 52C in turbo 1:13min without fan. With fan 1:30min. Ambient temp 7C. (outdoors)
From 23C to 52C in 50% 2:23min without fan. With fan 4:41min. Ambient temp 23C. Sabilizing around 55C.
So in turbo the difference is very small, but in 50% which is more than 8000lm it almost doubles the runtime, and please note it was indoors. Outdoors I believe you can run it below 52C for ever at 50-60%.

As I say in the title I would be willing to sell this flashlight if I get a generous offer. I put a lot of work in it, around 60-70 hours and as a reference the matterials alone costed me more than 150$. If you want to make an offer with PM feel free.

-Air cooled 4x XHP50.2: http://budgetlightforum.com/node/56829
-SkyRay King 4x XPL HI, TN40 clone: 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

Edited by: Kourtinoksylo on 11/01/2017 - 18:33
Nicolicous
Nicolicous's picture
Offline
Last seen: 2 hours 49 min ago
Joined: 04/16/2016 - 08:28
Posts: 1041
Location: Australia

wow it look cool man Thumbs Up

robk
Offline
Last seen: 3 weeks 2 days ago
Joined: 07/12/2013 - 15:51
Posts: 204
Location: New Hampshire

Awesome. I expect Justin’s spirit is smiling. Lovely work.

pinkpanda3310
pinkpanda3310's picture
Offline
Last seen: 6 hours 8 min ago
Joined: 12/28/2013 - 08:45
Posts: 1472
Location: Perth

“Its a little “Frankestein” looking, some will find it ugly, personally its not my favorite looking piece, however 100% innovative…”

For a fan cooled light I think it looks pretty good Sushi

Nice idea and well executed Star

The Miller
The Miller's picture
Offline
Last seen: 1 month 1 week ago
Joined: 12/14/2015 - 12:08
Posts: 9631
Location: Charente France

Awesome!
Think it looks very nice

Can you tell more about temps?

MRsDNF
MRsDNF's picture
Offline
Last seen: 1 hour 40 min ago
Joined: 12/22/2011 - 21:18
Posts: 12091
Location: A light beam away from the missus in the land of Aus.

That is one very creative build Kourtinoksylo. OL would be very happy to know you inspired him and of what you have made.
That fan you have used looks like an amazing item. A little different to the one I’m using.
Thanks for posting it up and looking forward to seeing more of your creations. 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.

 

KawiBoy1428
KawiBoy1428's picture
Offline
Last seen: 6 hours 6 min ago
Joined: 04/11/2014 - 18:05
Posts: 2698
Location: The Motor City

That is one bad mamma jamma there! Beer

Your like riding the ragged edge of POOFDOM at 10amps per LED!!!!

BRAVO!! Thumbs Up

I wouldn’t run 8-30Q’s or VTC5A’s !

KB1428 “Live Life WOT”

WillyD
Offline
Last seen: 3 hours 33 min ago
Joined: 10/10/2012 - 15:55
Posts: 706
Location: Ohio

I think this is one of my favorite builds in a long time! Any way you would be able to create a youtube video with the fans running? I’d like to see it all in action. And, excellent use of your tools as well.

pommie
Offline
Last seen: 8 hours 48 min ago
Joined: 08/28/2013 - 03:56
Posts: 928
Location: Corio, Victoria, Australia

Nothing to see here folks, move along...

leroycp
Offline
Last seen: 54 min 13 sec ago
Joined: 12/27/2015 - 19:24
Posts: 620
Location: Stewart TN

Me like! One of the best I have seen. Two thumbs up.

AlexGT
AlexGT's picture
Offline
Last seen: 2 hours 48 min ago
Joined: 06/07/2012 - 17:39
Posts: 3655
Location: Texas

AWESOME BUILD! Justin (Old Lumens) is smiling at you! SmileBeer

lostheplot
lostheplot's picture
Offline
Last seen: 4 hours 1 min ago
Joined: 08/09/2012 - 07:29
Posts: 455
Thumbs Up

sorry all images down
thanks photobucket

bwings
Offline
Last seen: 1 day 22 min ago
Joined: 01/31/2016 - 04:42
Posts: 102
Location: South Sumatra, Indonesia.

Awesome!
very creative build, looks like a badass weapon from ‘Doom’ Big Smile

Next project: Water Cooling LOL

____________________________________________________________________________________

Sorry for my poor English

xxx
xxx's picture
Offline
Last seen: 43 min 48 sec ago
Joined: 03/17/2013 - 08:20
Posts: 355

Creative

Like the way you cut thats SRK

Majoroverkill
Majoroverkill's picture
Offline
Last seen: 2 months 1 week ago
Joined: 01/12/2017 - 17:13
Posts: 491
Location: Nevada

I like it! I like it a LOT!! Great job Big Smile

Doug S.

Jtm94
Offline
Last seen: 3 hours 22 min ago
Joined: 02/22/2017 - 05:08
Posts: 302
Location: Pennsylvania

Really interested in what this pushes the maximum safely sustainable output to.

Box
Offline
Last seen: 1 week 4 days ago
Joined: 08/26/2014 - 06:53
Posts: 634
Location: Australia

That’s amazing! Love very creative

FPV
FPV's picture
Offline
Last seen: 20 min 55 sec ago
Joined: 07/14/2017 - 12:36
Posts: 520
Location: Traveling on the job

such an innovative way, very nice mod.

The_Driver
The_Driver's picture
Offline
Last seen: 20 hours 36 min ago
Joined: 10/20/2016 - 05:51
Posts: 852
Location: Germany

Very nice! Thumbs Up

southland
southland's picture
Offline
Last seen: 7 hours 58 min ago
Joined: 11/04/2012 - 07:15
Posts: 3126
Location: Georgia, USA

Really great build and I also like the looks.

gregor
gregor's picture
Offline
Last seen: 13 hours 55 min ago
Joined: 01/09/2015 - 16:35
Posts: 493
Location: Slovenia

Amazing, very nice Thumbs Up

djozz
djozz's picture
Offline
Last seen: 10 hours 31 min ago
Joined: 09/07/2012 - 17:04
Posts: 12118
Location: Amsterdam

Extremely nice and effective build! Thumbs Up

Flashy Mike
Flashy Mike's picture
Offline
Last seen: 3 days 9 hours ago
Joined: 01/14/2016 - 16:38
Posts: 936
Location: Germany

Great build!
Would you mind to elaborate which SRKs you used and how you connected the tubes?

solRNY
Offline
Last seen: 13 hours 2 min ago
Joined: 03/27/2017 - 17:24
Posts: 154
Location: Syracuse, NY

that’s way cool!

Sukoi
Offline
Last seen: 22 hours 3 min ago
Joined: 09/28/2016 - 03:32
Posts: 157
Location: N. Europe

beauty and the beast….thanks for showing off Beer

Kourtinoksylo
Offline
Last seen: 15 hours 4 min ago
Joined: 02/25/2017 - 15:33
Posts: 78
Location: Greece/Germany
Flashy Mike wrote:
Great build! Would you mind to elaborate which SRKs you used and how you connected the tubes?

I inserted some 3mm screw rods in the exsisting holes of the spring board and let them stick out around 12mm as you can see on the picture. I then drilled four 5mm holes roughly at the appropriate spots at the second tube as you see on the same picture. 5mm allows some room to play and find the perfect fit. I filled the 5mm holes with epoxy and placed the tube with the screws on top of, with the screws being inside the epoxy. After it hardened they became inseparable. I suppose if i heat the pieces a lot and melt the epoxy I can separate them if needed…
The SRKs I used where the cheapest I found on aliexpress that had the smooth type tube. Were around 15-17 dollars a piece. They are I think 10 or 11x XML(they had fake XMLs so sacrificing them was not a problem).

Thank you all for the kind words.

-Air cooled 4x XHP50.2: http://budgetlightforum.com/node/56829
-SkyRay King 4x XPL HI, TN40 clone: 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

Geuzzz
Geuzzz's picture
Offline
Last seen: 16 min 14 sec ago
Joined: 10/25/2015 - 10:27
Posts: 378
Location: Netherlands

Fantastic build!

FmC
FmC's picture
Offline
Last seen: 5 hours 40 min ago
Joined: 03/31/2013 - 05:23
Posts: 2062
Location: Brisbane, AU

Cool build. Would be nice to see more pictures if you have any. Beer

Firelight2
Firelight2's picture
Offline
Last seen: 3 hours 58 min ago
Joined: 04/08/2011 - 15:17
Posts: 2551
Location: California

Absolutely awesome build!

Wonderful work with that heatsink and active cooling. OL would be proud! Cool

How long can it run on turbo with the fan speed set to high?
Got any outdoor beamshots at turbo?

Flashy Mike
Flashy Mike's picture
Offline
Last seen: 3 days 9 hours ago
Joined: 01/14/2016 - 16:38
Posts: 936
Location: Germany

Kourtinoksylo wrote:
I inserted some 3mm screw rods in the exsisting holes of the spring board and let them stick out around 12mm as you can see on the picture. I then drilled four 5mm holes roughly at the appropriate spots at the second tube as you see on the same picture. 5mm allows some room to play and find the perfect fit. I filled the 5mm holes with epoxy and placed the tube with the screws on top of, with the screws being inside the epoxy. After it hardened they became inseparable. I suppose if i heat the pieces a lot and melt the epoxy I can separate them if needed…
The SRKs I used where the cheapest I found on aliexpress that had the smooth type tube. Were around 15-17 dollars a piece. They are I think 10 or 11x XML(they had fake XMLs so sacrificing them was not a problem).
Thanks for the info. So the electrical contact for batt- is done only by the 2 tubes connected with epoxy? Since I have a somehow similar mod in my mind I wonder if over the time the pressure between the 2 tubes decreases and the contact resistance rises.
The tubes are nice, they look similar to the Q8.
southland
southland's picture
Offline
Last seen: 7 hours 58 min ago
Joined: 11/04/2012 - 07:15
Posts: 3126
Location: Georgia, USA

Deserves a bump.

Pages