Water Cooled Flashlight Modding a MT35 PLUS aka MF04

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CNCman
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Water Cooled Flashlight Modding a MT35 PLUS aka MF04

I am going to do a mod that will take a few weeks to finish the first of 3 mods to the same light. Is the featured mods the correct place to start this thread ? Thanks Beer

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CNCman
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I am a newbie here to Lithium powered flashlights and BLF. So you will see many missteps and screw ups and please let me know so the error will not be repeated. When I first found BLF, I was so happy to see all you good people helping each other, I wanted to join and try to contribute something. So after buying a MT35 PLUS and using it, well it would shine far but not bright. Looking to mod it we found this http://budgetlightforum.com/node/57036 and the idea was born in this thread. This will be a 3 part build. Part 1 will be to design and build a water cooling system with pump using a 12v 7amp driver from Lexel to power the pump and XHP70.2 led. If the cooling is successful then proceed to Part 2 which is an upgrade to a CTF-90 and 40 amp driver. And finally part 3 which will be adding the Aspheric lens http://www.optolife.com/singlet_lens/A380.html or http://www.optolife.com/singlet_lens/A037.html. The reason for not going to the CFT-90 first is we didn’t think it could be cooled, even with water. So here are a few pics of the progress so far.

Planning and design, using Solid Edge 2D Drafting FREE CAD software https://www.plm.automation.siemens.com/plmapp/education/solid-edge/en_us... for all drawings.

Programs used to make the upper copper cooler half only.
This will hold a copper 17mm mcpcb with the XHP70.2 12v led.
The MT35 head will get a hole bored in it to accommodate the copper cooler.


AFT end, first operation.

FWD end, second operation.




Bottom half, stilled needed tube holes drilled in this pic.


More pics coming.

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EasyB
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Interesting project. The copper heat exchanger looks really cool. How do you plan to move the heat from the water to the air?

Why do you want to use an aspheric lens? It will increase throw by a bit? Light collection efficiency of a lens like this is only 25-30%. Whereas a reflector puts 70+% of the light into the beam. If you really want to use a lens I might consider using a precollimator lens which can double the light collection efficiency.

LichtAn
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Holy smokes, this will be interesting.

thijsco19
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Looks great!!

LichtAn
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How will the pump be mounted and where?

CRX
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Cool project Thumbs Up

CNCman
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LichtAn wrote:
How will the pump be mounted and where?

The pump will be externally mounted somewhere, I have not tackled that one yet, but somewhere opposite the button switch.

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Enderman
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Nice project! What rads do you plan to use for cooling?

CNCman
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EasyB wrote:
Interesting project. The copper heat exchanger looks really cool. How do you plan to move the heat from the water to the air?

Why do you want to use an aspheric lens? It will increase throw by a bit? Light collection efficiency of a lens like this is only 25-30%. Whereas a reflector puts 70+% of the light into the beam. If you really want to use a lens I might consider using a precollimator lens which can double the light collection efficiency.

The heat will be displaced from an aluminum coil mounted around the head, but no fan for that.
I wanted to have it zoom-able for flooding and throw, not sure how effective it will perform for either one until its finished.

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CNCman
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Enderman wrote:
Nice project! What rads do you plan to use for cooling?

1/4 in diameter soft aluminum tubing wound around the head 2 times with .100 in gap between coils. No fan.
I have been trying to learn from your builds so we all kinda work together and share. Beer

The coil is in work to get finished this weekend if everything goes as planned.
Using the head for the mold.

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TheOnlyDocc
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How much heat (W) do you want to dissipate with the coil? Build a few watercooler for CPUs and Motherboards myself a few years back. And also build a lot of custom cooling solutions. Interested to see how you fit it together.

New LuckySun D80 looking good so far http://budgetlightforum.com/node/66255

Enderman
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CNCman wrote:

1/4 in diameter soft aluminum tubing wound around the head 2 times with .100 in gap between coils. No fan.
I have been trying to learn from your builds so we all kinda work together and share. Beer

The coil is in work to get finished this weekend if everything goes as planned.
Using the head for the mold.
![img]https://i.imgur.com/WrxrbNJl.jpg[/img]!


Nice.
Is that like 25ft of coil?
Should definitely be enough for a CFT90 as long as you don’t do more than 30-40A
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“TheOnlyDocc” Sorry, I’m not able to know the amount of heat except from reading and guessing how much trouble
everyone is having with thermal step down after a few minutes run time. I’m not sure this idea will work at all, but I could not
resist the opportunity to try and maybe throw some information into the hat for everyone to use.

“Enderman” Yes it is a 25ft roll. Trying to squeeze as much as possible on it and not take away too much flashlight appearance. I have yet to solder the spacers in place and form it into shape. I will give the total feet used for reference so the guys who know how can do those if we can give them accurate info. Beer

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CNCman
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Aluminum soldering proved too difficult so small stainless steel wire was used to assemble cooling coil.

Ready for heating with Kester EP256 Lead Solder Paste 63/37.


Alignment marks.

On the small stove eye. Used .062 aluminum plate and pretested melting point at Medium setting.
About 1 minute to attain temp and immediately turned it off after test spot on top melted.



Finished with XHP70.2 in place, but will use Arctic MX4 Thermal Compound Paste later at assembly.
A large mcpcb for 12v was not available or it could have been used and designed differently.

Battery tube in work now.


One at a time in soft jaws in the center of the vice.


Ready for threading.

More pics next week. Still a lot to mod before completion.

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AlexGT
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Interesting, Keep up the good work!

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Epic build Smile Will be following this Cool

TheOnlyDocc
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I noticed that you are using copper and Aluminium in the same loop. This will get you corrosion fast. Had the same problem in a PC watercooling loop. Even with very high quality additives. It takes longer but eventually it happens. And the solderjoint that have contact with the water will also be a week point.

New LuckySun D80 looking good so far http://budgetlightforum.com/node/66255

CNCman
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TheOnlyDocc wrote:
I noticed that you are using copper and Aluminium in the same loop. This will get you corrosion fast. Had the same problem in a PC watercooling loop. Even with very high quality additives. It takes longer but eventually it happens. And the solderjoint that have contact with the water will also be a week point.

Yep , that’s a good point. I had read some on this subject, mostly for best heat transfer. Corrosion was mentioned often as a concern and freeze preventative which can lower cooling efficiency. Probably will use automotive coolant and empty the system while in storage and flush it clean, but not sure what corrosion preventive to use at flush and leave dry.

:ARROW-RIGHT: This is all a guess for me, so if anyone has a suggestion please feel free to say something, I’m just a newbie here, I can machine things but I know little about flashlights.

CNC & Manual Machinist. Think outside the box too long , cannot find your way back in.

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So, has the project been finished or not?

I’d like to know Smile

My very own high current Beryllium Copper springs Gen 3:
http://budgetlightforum.com/node/67401
Liitokala Aliexpress Stores Battery Fraud: http://budgetlightforum.com/node/60547

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Looking Awesome CNCman. Can’t wait to see the finished build.
Have you got any updates on this project.
Very good pics by the way. Thumbs Up

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Will it have a steam whistle for overpressure release?

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I just ran across this. Very ambitious build. Some good ideas I see here. I’m curious to see how it will work. I’m wondering if convection would be enough to move heat without a pump. Probably not,but it probably doesn’t need a lot of flow to be effective.

CNCman
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Sorry guys for not responding. We have had a few Life Events and are just recovering from it all. I will now begin finishing the light and post pics on the progress in a few days. Facepalm

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mattadores
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Hey, this looks like an amazing project! Very excited to see how it progresses!

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Great build!
I am really curious about end result. I think you could have been bought a 6V bigger MCPCB and mod it to 12V. Not a big deal. Just two cuts with a dremel and a thick wire.