Mod: Olight SR Mini with triple SST-40 and host bypass.

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Mike C
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Mod: Olight SR Mini with triple SST-40 and host bypass.

I received a SR Mini some year ago with a broken driver and no LEDs to play with. I didn’t know what to do with it as it’s a little too big for the standard triple and it the time I didn’t make E-switch only drivers, so in the drawer it went to collect dust.

I only recently learned about the SST-40 LED’s characteristics and XM-L compatible size, but when I did I immediately thought of the SR Mini in my drawer and ordered three SST-40s on MCPCBs. However, when I took the light apart I noticed that the empty MCPCB in this light was a good copper MCPCB with direct thermal path, so I decided to move my LEDs over to it instead of gluing on the three seperate MCPCBs. However, it was for LEDs in series so I hacked up some traces and scraped away some coating to make all LEDs in parallel with solder points.

MCPCB is screwed in place too, so it’s a nice fit. Each LED got it’s own set of 22 awg wires:

I combined the three + wires and three – wires to 18 awg wires and drilled out the hole a little:

Before considering making a custom driver I decided to build it with one of my existing FET + 8 × 7135 drivers and use the original as BAT+ contact plate, which I hacked up a little to accommodate spring bypass wires:

The BAT+ contact plate put together (solder blobs added later):

This light comes with a USB charger port. My own drivers don’t (yet) support USB charging so I ripped it out. However, it’s location is interesting, it’s on the side of the battery tube:

On closer inspection it turned out that the hole for the USB charger wires actually runs through the entire host:

So I ran a 18 awg GND wire from the driver through this hole all the way to the back, soldered it to the back plate together with the rear spring bypass wires, essentially creating a host bypass. I now have both BAT+ and BAT- in direct contact with my driver with 18 awg wires. I just had to remove one of those plastic battery spacers that prevents the contact board from rotating when screwing on the tailcap:

Assembling is a little tight, but there is enough room for the wires to twist while screwing it together. A custom made driver will make this easier, but it’s currently good enough for testing so I just added some kapton tape to prevent any shorts to the host:

As everything is now held together by wires it’s a little finicky to pull a part and put back together. The longer the wires, the more finicky it gets, but I wanted some extra so I can chop it up a little once I get the custom driver made. Rather too long than too short!

In with some three freshly charged LG cells and check amp readings. I took my clamp meter and measured the amps for 1, 2 and 8 × 7135s turned on and the readings where accurate, so I slammed on boost mode with FET full on. Man, it puts out light! The clamp read 24.5 amps. That’s just over 8 amps per LED, and is about where I wanted to be since djozz tested an SST-40 to it’s death at 9.5 amps.

It’s a nice size for the hand, and with three 18650 cells I’ll get decent run times during normal use, and a lot light when I want it. So far I like it so I’m going to design my own custom driver for it as it might very well be my go to light for my exploration trips underground.

Update 12/22/2017
I’ve now taken some beamshots with 2 other lights for comparison: A M2 quad XPL-HI 5000K with 10621 Carclo lens that pulls around 10 amps, and my BMF SRK with 3 x MT-G2 5000K that pulls around 15 amps. I set a little too fast shutter speed because the photos don’t look like much but they are OK for comparison as all photos are taken with the exact same settings set manually. I can’t set a white balance number of my choice with my camera so I selected daylight 5200K.

M2 quad:

BMF SRK:

SR Mini:

M2 quad:

BMF SRK:

SR Mini:

Edited by: Mike C on 12/22/2017 - 05:57
Mike C
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Reserved for future upgrades…

I’ve designed and ordered a custom driver for it. It’s based on my ATtiny1634 drivers with a FET and 8 × 7135. The screw holes where not on aligned so instead of risking having with slightly off I skipped them altogether and will drill them manually when it’s in place. I’ve also added some vias for output pins as I plan on adding a multi color lighted switch with color control.

sovereignknight
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Night shots! Bring on the night shots!

https://en.wikipedia.org/wiki/John_3:16 

Flashlights:

x6 Sk68 modded 3 Nichia 319AT, 3 Cree XP-G3 - x1 Solorforce P60 drop in custom XM-L2 U4 1C, Qlight Rev.A 7135*8 3.04A Driver - x2 Lumintop EDC05 - x2 Jaxman E2L tripple XP-G2 S4 
x1 Jaxman Z1 Zoomie, Cree MT-G2 Q0 LED - x1 Acebeam K40m thrower with MT-G2 Q0 LED - x1 Xintd SC-82 V5 Limited Edition C8, XM-L2 U4 1C, Qlight Rev.A 7135*8 3.04A Driver
x1 Convoy L6 moded with a Cree XHP-70.2 P2 1D LED - x1 Rare Olight x7 Maurauder with a Nuetral White LED - x1 Astrolux MF-01 Nichia 219c - x1 Astrolux MF-01 Cree XP-G3 - x2 Zebralight SC5w MKII  

x1 Lumintop Tool AA  Olight i3E EOS - x2 Zebralight SC600w Plus MK IV XHP 50.2 4500k 80 CRI - x1 Fenix CL30R

CRX
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Nice mod Thumbs Up

Mike C
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sovereignknight wrote:
Night shots! Bring on the night shots!

Alrighty, I’ll get it done within a few days. I’ll take a triple, a quad and my BLF SRK (triple MT-G2) and make some comparison shots.
FmC
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Nice mod Thumbs Up

I have 3 SST 40’s sitting here, & don’t yet know what to put them in…

EasyB
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Nice mod. Really driving those SST40s to their full potential. Thumbs Up

Mike C
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Thanks guys!

FmC wrote:
I have 3 SST 40’s sitting here, & don’t yet know what to put them in…

Put them to use! Seeing that clamp meter measurement is a joy in it’s self Smile
DENGOH
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Host bypass Big Smile

cool i'll see you when you get there

MRsDNF
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Nice mod Mike. Good to see the old host put to s good use. Silly

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.

 

18sixfifty
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Nice mod and great job overcoming the obstacles in the way of making this possible.

I’m a junky, I mod lights so I can sell lights so I can buy more light to mod so I can sell lights to buy more lights to mod.

Majoroverkill
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Do you have any beam shots of this little monster? Cool

Doug S.

Mike C
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Thanks guys!

Majoroverkill wrote:
Do you have any beam shots of this little monster? Cool

Coming. Right now I’ve taken it apart to make measurements of the original driver I used as battery contact plate. When I like a light this much I feel it deserves it’s own dedicated driver instead of a loose driver attached only by wires. I hope to get the beam shots done this weekend though!
Mike C
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Beamshots added to bottom of OP… Unfortunately a little too fast shutter speed so they are a little too dark but I have comparison shots with two other lights taken with the same camera settings.

I’ve also designed and ordered a custom driver for it. It’s based on my ATtiny1634 drivers with a FET and 8 × 7135. The screw holes where not evenly aligned with anything else on the original driver so instead of risking having with slightly off I skipped them altogether and will drill them manually when I’ve put it in place. Besides the programming vias I’ve also added some from unused output pins as I plan on adding a multi color lighted switch with color control.