Elektro lumens Big Bruiser upgrade project

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Rat
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Elektro lumens Big Bruiser upgrade project
Hi Guys

I am looking at upgrading one of my all-time favourite lights the Elektro lumens Big Bruiser.
I love the simplicity of this light and the one-handed operation of it so looking at keeping that the same. I am thinking the same one mode only MAX. Runtime is not important just raw mind-blowing power.

So what to do with it That’s where you guys come in any ideas? They would be greatly appreciated.

I have some of the ELBB3 circuit board coming from Wayne ( see below) the 3x XML LEDs ones so it could be just as simple as the latest XML chip upgrade which would be ? not sure what the best XML-2 chip is these days and if it would be a big enough difference?

Or we could go all out and do something big?

1: Not sure if it would be possible to run 3x XHP70.2 chips? There is room for a driver/booster but I suppose the bottleneck will be the one cell 26650 battery.

2: Maybe the XHP50.2 could work somehow? I am sure if I have a new heat sink machined up I could fit a reflector around 38mm wide and 25-30mm long in it maybe the XHP35 HI would work?

I was planning to still use the 19 degrees Ledil triple optics but not if there is a better option.

So, guys, I need the smarts of you all to help me out here as I have never done much in the modding world before but think it’s time I started and I could not think of a better light to upgrade. I do have a second bruiser that I have never used so I will be modding my user first up.

Original sale thread here

A review here

ELBB3 circuit board

Massive heat sink it goes down inside another 22mm

The Big Bruiser

Edited by: Rat on 11/11/2017 - 07:38
The Miller
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That light is really beautiful!

atbglenn
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A buddy of mine has one of the first Big Bruiser’s Wayne built without anodizing. It looks amazing. Next time he comes over I’ll have him bring it. I’ll take a couple of pictures.

FPV
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I have never seen this light before, very nice. Need to explore more about it.
Thanks for sharing.

Rat
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atbglenn wrote:
A buddy of mine has one of the first Big Bruiser’s Wayne built without anodizing. It looks amazing. Next time he comes over I’ll have him bring it. I’ll take a couple of pictures.

The Raw version looks great as well. Has he modded it.

Yes they are a cool looking light.

I think just replacing the LED’s is not going to cut it. I am going to turn this light into a thrower well try too.

So the new plan is have a new heat sink made (copper). I will need to take some of the mass from the top but I can have more mass at the base of the heat sink as the original is hollow.

Question?
If I go with the XHP35 HI and just want one mode max what booster/Driver should I be looking at? It only takes 1x cell 26650 battery

Thanks for any help.

EasyB
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If you are limited to one cell a triple or quad XPL2 or SST-40 will get you the most output. With a low IR cell it should pull ~18A and make ~5000 lumens out the front (triple configuration). If you want more throw go with the SST-40 and dedome them.

A boost driver that would fit in the light would not be able to output that power.

djozz
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The Big Bruiser dates from before the DTP boards, right? In that case you will be limited to maybe 4 amps per led.

EasyB
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djozz wrote:
The Big Bruiser dates from before the DTP boards, right? In that case you will be limited to maybe 4 amps per led.

I think it is just a CUTE 3 optic, so maybe he could get a new triple MCPCB.
djozz
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EasyB wrote:
djozz wrote:
The Big Bruiser dates from before the DTP boards, right? In that case you will be limited to maybe 4 amps per led.

I think it is just a CUTE 3 optic, so maybe he could get a new triple MCPCB.

In that case the only dtp option is the big triple Noctigon, in which case XM-L is no option and XP-L(2) may be the best led (think 4500 lumen)
Rat
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EasyB wrote:
djozz wrote:
The Big Bruiser dates from before the DTP boards, right? In that case you will be limited to maybe 4 amps per led.
I think it is just a CUTE 3 optic, so maybe he could get a new triple MCPCB.
djozz wrote:
EasyB wrote:
djozz wrote:
The Big Bruiser dates from before the DTP boards, right? In that case you will be limited to maybe 4 amps per led.
I think it is just a CUTE 3 optic, so maybe he could get a new triple MCPCB.
In that case the only dtp option is the big triple Noctigon, in which case XM-L is no option and XP-L(2) may be the best led (think 4500 lumens)

Looks like I do not have many options with just the one cell.

Do I need a driver or anything for this build? Can you guys check my parts list to make sure I have everything?

3x XP-L(2
triple Noctigon
1x LEDIL CUTE OPTIC
2x Battery ? Low IR cell do you have a link

Again thanks for your help.

EasyB
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Rat wrote:

Looks like I do not have many options with just the one cell.

Do I need a driver or anything for this build? Can you guys check my parts list to make sure I have everything?

3x XP-L(2
triple Noctigon
1x LEDIL CUTE OPTIC
2x Battery ? Low IR cell do you have a link

Again thanks for your help.


Most of the pictures in the review don’t work for me, so I’m not sure how the light is put together. Is it just a simple twist to turn on (no buttons)? You don’t need a driver if you are fine with just on-off functionality.

The LEDs you have linked are XPL HI. The XPL2 will pull more current and give more output (lumens), but they won’t throw as far as the XPL HIs. Some estimates: with XPL HI, ~3000 lumens and 42Kcd. With XPL2, ~4500lumens and ~24Kcd. So it depends on what you want out of the beam. In either case, ask Richard from mtnelectronics to reflow the LEDs on the triple noctigon you linked. The optic you linked also looks good.

As far as the cell, this shockli is a great cell because it has a lot of capacity and pretty low IR. But if you want to maximize the output there are cells with lower IR. This cell is one of the best in that regard.

Rat
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EasyB wrote:

Most of the pictures in the review don’t work for me, so I’m not sure how the light is put together. Is it just a simple twist to turn on (no buttons)? You don’t need a driver if you are fine with just on-off functionality.

The LEDs you have linked are XPL HI. The XPL2 will pull more current and give more output (lumens), but they won’t throw as far as the XPL HIs. Some estimates: with XPL HI, ~3000 lumens and 42Kcd. With XPL2, ~4500lumens and ~24Kcd. So it depends on what you want out of the beam. In either case, ask Richard from mtnelectronics to reflow the LEDs on the triple noctigon you linked. The optic you linked also looks good.

As far as the cell, this shockli is a great cell because it has a lot of capacity and pretty low IR. But if you want to maximize the output there are cells with lower IR. This cell is one of the best in that regard.

Yes, it’s is a simple on-off twisty so no driver it is.
Thanks for the heads up on the XPL2. Max lumens it is. That Aspire is the battery I will order.

Thanks, EasyB. I am a major newbie I spent hours last night on this forum reading peoples builds and info on LEDs and so on. Went to bed with my head still spinning and could not sleep so much to sink in.
I plan on getting a lathe soon just need to find a good second-hand one with all the tools and a way to break the news to my wife. So all I can learn now will help out big time with future builds.

Again thanks, everybody you guys are the best.

Rat
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Ok stupid question time can I flow the XPL-2 leds on the XML MCPCB above they are a smaller die compaired to the XML?
I forgot about the hole in the center of the MCPCB. I cannot find one that has the hole or can I drill a hole in the center of the Noctigon XP32 32mm Advanced Copper MCPCB.

thx

EasyB
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Rat wrote:
Ok stupid question time can I flow the XPL-2 leds on the XML MCPCB above they are a smaller die compaired to the XML?
I forgot about the hole in the center of the MCPCB. I cannot find one that has the hole or can I drill a hole in the center of the Noctigon XP32 32mm Advanced Copper MCPCB.

thx


XML and XPL have different package sizes so you can’t put one on the other. The real problem is the MCPCB that your light came with probably does not have DTP (direct thermal path) between the LED and the metal of the MCPCB. This limits the output you can get from the LEDs.

You can drill a hole in the noctigon. Why do you need a hole?

everydaysurvivalgear
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You could always use a triple XHP50.2 setup and use two of the half sized 26650 cells i forgot there name. Even at stock current it would output around 7500 OTF lumens 6v at 7.5amps? You could use your stock MCPCB with XHP50.2

EasyB
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everydaysurvivalgear wrote:
You could always use a triple XHP50.2 setup and use two of the half sized 26650 cells i forgot there name. Even at stock current it would output around 7500 OTF lumens 6v at 7.5amps? You could use your stock MCPCB with XHP50.2

A couple problems with the triple XHP50 setup. I don’t think they will fit under the CUTE3 optic without removing the dome. The 26350 cells really can’t handle much more than 8A. A triple XHP50.2 will essentially be shorting these batteries; I wouldn’t do it. It would be bright if driven correctly, but I’m not sure where you got the 7500 lumens and 7.5A from. Also he would still have to worry about the non-DTP MCPCB present which would not work with the high power of the XHP50.2 I think.

Rat
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EasyB wrote:

XML and XPL have different package sizes so you can’t put one on the other. The real problem is the MCPCB that your light came with probably does not have DTP (direct thermal path) between the LED and the metal of the MCPCB. This limits the output you can get from the LEDs.

You can drill a hole in the noctigon. Why do you need a hole?

The heat sink currently has the holed drilled in the center for the wires so it will be just easier.

Ok settled I will order all the parts tomorrow XPL-2 it is.

I ended up with KeepPower 3.7V High Drain IMR Max Discharge 30.0A & Max. Plus Discharge 50.0A so a little higher than the Aspire but they would not deliver to me in Australia. As I am going direct drive what gauge wire should I use as the positive power wires? Was thinking I might need to use the wire as a resister or bigger the better? 24AWG-TN ?

everydaysurvivalgear wrote:
You could always use a triple XHP50.2 setup and use two of the half sized 26650 cells i forgot there name. Even at stock current it would output around 7500 OTF lumens 6v at 7.5amps? You could use your stock MCPCB with XHP50.2

WOW! Half size 26650 sweet. Found them 26350 2000mAh. Ok I have two Big Bruisers so now I am thinking 2× 26650 runing a XHP35 HI on the second one ?
What do you guys think will the XHP35 HI work with the 2× 26650 any idea what driver will work with the two ? I am thinking the XHP35 HI with a single spot optic one mode HI.

thx