The SYNIOSBEAM - CFT90 recoil thrower

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Agro
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Do you need a rigid arm at all?
Maybe you could mount the wires/tubing to the lens too? Wink

Or maybe use 3 bicycle spokes / steel ropes / …?

Agro
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Enderman wrote:
Lightbringer wrote:

T-nuts.

 

Ah good idea.
Another thing I forgot to mention is that I wanted it to be metal because that’s what cools the fluid, copper pipes running on the inside of the body.
This may not always be the case for future builds though.

Maybe you could take the pan, mount tubing to it and then add fiberglass over them together?
Enderman
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Agro wrote:
Do you need a rigid arm at all?
Maybe you could mount the wires/tubing to the lens too? Wink

Or maybe use 3 bicycle spokes / steel ropes / …?


If the lens is rigid enough no, but it’s only 3mm acrylic so the aluminum is helping reinforce it from behind.
If it was glass then it would 100% need the aluminum spider.

The thing is, the wires and tubing will block light regardless, so if there is a single arm and the wires/tubing run inside the arm it just makes things neater without really changing the performance.
Maybe in future builds (if I do a retro-reflector again, which is pretty likely) I may do a single arm config. Sorta like this but without the extra bar:

Reducing the size of the middle circle where the LED is can also help improve the usable surface area (but not in this case, because my LED block is not bigger than the reflector hole)

Agro
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Now you have 3*support area which is strictly larger than 3*tube area.
It shouldn’t be a problem to have little more than 2*tube area blocked because wires can be in the back of the tubes.
Have you considered rigid rectangular tubing? This should enable reducing blocked area even more without increasing thickness. Or maybe have more flexibility in the area-thickness tradeoff.

Enderman
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Agro wrote:
Now you have 3*support area which is strictly larger than 3*tube area.
It shouldn’t be a problem to have little more than 2*tube area blocked because wires can be in the back of the tubes.
Have you considered rigid rectangular tubing? This should enable reducing blocked area even more without increasing thickness. Or maybe have more flexibility in the area-thickness tradeoff.

The tubes are .25” diameter, same as the supprts.
As I said earlier in this post The only tubing I could get at the time was .75” wide which would have taken up the same space as three .25” arms.
If I wanted thinner I would need to stack the tubing and wires and then have to worry about the space between the reflector and glass.
It simply worked out better for strength, ease of centering, and connections to the waterblock to have 3 thin arms instead of 1 thicker one.

If it was a single arm I would need to do some fancy stuff to the waterblock in order to have both inlet and outlet on the same side, currently they are 120 degrees apart which made the machining a lot simpler.

Enderman
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BUILD PROCESS – the reflectors

These are the two PA17.02 aluminum coated reflectors with mounts.
I bought two because I am building two prototypes of this light, one for me and one for someone else.







Datasheet: http://www.phoenixelectroforms.com/uploaded/PA17%20SERIES1.pdf

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BUILD PROCESS – the waterblocks

Here are the two waterblocks for the LED, one of them has the barbs screwed on.
If you look at it one way, it looks like a smiley face C: if you look at it the other way it looks like a sad face :C
If I use copper in the future I will need to find a way to machine it myself, because this was a bit too expensive IMO, not worth $133 for a ~$1k flashlight.
They did turn out really good though.




ImA4Wheelr
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^

Oh my, those reflectors are stunning.  The cooper bases look great too.  Serious business going on here.

Enderman
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BUILD PROCESS – waterjetting















Unfortunately I accidentally waterjet an old drawing file which had some holes in the wrong spots and was missing a few new holes, so I had to do some manual work to drill additional holes.
I will hopefully have the whole body finished by tomorrow so that I can start mounting components and do the electrical and cooling stuff.

MRsDNF
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That beats machining. Looking real good to me. Smile

 

djozz quotes, "it came with chinese lettering that is chinese to me".

                      "My man mousehole needs one too"

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.

 

Enderman
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ImA4Wheelr wrote:

^


Oh my, those reflectors are stunning.  The cooper bases look great too.  Serious business going on here.

MRsDNF wrote:
That beats machining. Looking real good to me. Smile

Thanks Smile
Hopefully today I get the machining done, only 16 more holes to drill and tap!
I’ve done like 50 so far Silly

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Love your project!. I am anxious for the results Big Smile

Max

luminarium iaculator
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Enderman you are surely not kidding here Wink

Hope you could earn few $ with your ideas or this is going to be very expensive hobby investment.

Modding is making something how you want it to be, not how it comes stock...

Old-Lumens

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FlashMax wrote:
Love your project!. I am anxious for the results Big Smile

Thanks! Smile

luminarium iaculator wrote:
Enderman you are surely not kidding here Wink

Hope you could earn few $ with your ideas or this is going to be very expensive hobby investment.


Haha thank you Smile It should pay off in the future, personal projects are really important to employers.
Or who knows, maybe I can start a business when I finish university, lots of options!
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BUILD PROCESS – electronics


Spent many hours tonight soldering, got about 50% of the electronics done.
Battery carriers, balance and change plugs, and switches.








MRsDNF
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Nice garage. I couldn’t see where the beer fridge was. Smile
Diggin the work. Thumbs Up

 

djozz quotes, "it came with chinese lettering that is chinese to me".

                      "My man mousehole needs one too"

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.

 

Enderman
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MRsDNF wrote:
Nice garage. I couldn’t see where the beer fridge was. Smile
Diggin the work. Thumbs Up

Haha thanks, I wish I had a garage with thousands of dollars of equipment like that.
Beer fridge is upstairs in another room Silly Don’t tell anyone though! It’s disguised as a pop vending machine!
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BUILD PROCESS – more electronics

About 50% done wiring now, and the body actually fits together well too, although it is not finished machining.
Planning how to fit and heatsink the drivers in the tiny 1 cubic inch of space I have left Silly

Only wiring left is attaching the voltage and temperature meters, pump, and LED driver to the white connector block.
And also the LED to the driver.

This week I will definitely finish the body and hopefully next week I can start working on the liquid cooling!





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FASTAAAA! Wink

Have you thought about polishing it to make it look fancy?
What about mounting the lens? Do you have O-Rings?

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The_Driver wrote:
FASTAAAA! Wink

Have you though abouth polishing it to make it look fancy?
What about mounting the lens? Do you have O-Rings?


It will get black anodized when it is done machining and test-fitting everything Big Smile

The lens will go on top of the spider.
I plan to put some neoprene tape on the spider so that the lens doesn’t directly constant the metal, this will act as a sort of o-ring.
Neoprene will work better than an o-ring because an o-ring this large will have trouble keeping it’s round shape.
The neoprene sticks on like tape so I just need to put a strip all the way around the spider and that will make it water resistant Smile

Since only one side is adhesive I will also have 6 screws around the front of the light keeping the lens from falling out.
This also means the lens is easily removable.

hIKARInoob
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Impressive stuff! Perhaps the folks of Mercedes are actually Illuminati? Big Smile

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Subscribed! Will be fun to see it’s performance as compared with a Maxabeam.

WWII 60" Carbon Arc (Sold), 1.6KW NightSun, 1KW VSS-3A, .8KW TrakkaBeam, 600W M-134 Light, 500W X-500-14s, 500W Starburst, 500W A120b, 450 Watt AEG German Leopard 1 Tank Light, 300W Locators, Megaray, 150W Communicator, Maxabeam Gen3, Pichel 75W Mini-Novas

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Enderman wrote:
It will get black anodized when it is done machining and test-fitting everything Big Smile

I meant polishing it before you anodize it. You will still be able to see the difference.

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hIKARInoob wrote:
Impressive stuff! Perhaps the folks of Mercedes are actually Illuminati? Big Smile

Haha thanks Silly it does look like their logo doesn’t it…

BVH wrote:
Subscribed! Will be fun to see it’s performance as compared with a Maxabeam.

Smile Can’t wait!

The_Driver wrote:
I meant polishing it before you anodize it. You will still be able to see the difference.

Ah ok, I will try to remove scratches and stuff with a scotchbrite pad but I think the anodizing place also offers some surface prep before anodizing, maybe I can get them to polish it for me.
Do you think polishing will make a big difference compared to just brushed?
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Enderman wrote:
I meant polishing it before you anodize it. You will still be able to see the difference. Ah ok, I will try to remove scratches and stuff with a scotchbrite pad but I think the anodizing place also offers some surface prep before anodizing, maybe I can get them to polish it for me. Do you think polishing will make a big difference compared to just brushed?

Do you own a maglite? Those are somewhat polished I think.

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What are your thoughts on the Maxiem waterjet? I’ve run an OMAX for a long time and Maxiem is what I guess you would call their value brand. The software looks to be almost identical which I would expect. They’re fantastically versatile machines that will cut just about anything, though I was defeated by a piece of carbide.

Enderman
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The_Driver wrote:

Do you own a maglite? Those are somewhat polished I think.

Yup, an old 4D one Silly
I think if I try polishing it then the flaws will become more visible.
Maybe for a future more refined prototype I can try doing that.
If everything is turned on a lathe and milled perfectly it would look best, which I didn’t do on this prototype unfortunately.

Turningbluechips wrote:
What are your thoughts on the Maxiem waterjet? I’ve run an OMAX for a long time and Maxiem is what I guess you would call their value brand. The software looks to be almost identical which I would expect. They’re fantastically versatile machines that will cut just about anything, though I was defeated by a piece of carbide.

Can’t really give a good opinion since the one I used has been mistreated and screwed up plenty of times by kids who don’t know what they’re doing.
But from my personal experience with this one, it is less accurate than the regular omax waterjets which I’ve also used previously.
If you just need quick cuts at large size then the maxiem works great for that.
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BUILD PROCESS – chassis

Almost done with the flashlight body, everything fits!
Only things left to do is clean up the surfaces with some scotchbrite and remove scratches.
With the body finished I can start working on the cooling and electronics.
Here you can also see the handle on the light, as well as the 6 screws which will hold the glass on the front.







luminarium iaculator
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Hmmm… Enderman I really did not think that you are crazy scientist but you obviously are… Thumbs Up

Modding is making something how you want it to be, not how it comes stock...

Old-Lumens

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luminarium iaculator wrote:
Hmmm… Enderman I really did not think that you are crazy scientist but you obviously are… Thumbs Up

Big Smile Thanks!
It will get more crazy, don’t worry.

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