6th Annual BLF / Old Lumens Scratch Made Light Contest - FmC's Hand Made entry.

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FmC
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6th Annual BLF / Old Lumens Scratch Made Light Contest - FmC's Hand Made entry.

 

 

Edited by: FmC on 10/29/2018 - 16:28
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 I got off to a late start this year, what with Jack, along with half of the parts I ordered for the build, going MIA.

The missing parts were one thing, but I've only myself to blame for Jack's absence. He'd made off in last year's build, with a bag of loot, & plans for a peaceful retirement...

 After some good times & bad decisions, Jack ended up getting stranded in a remote area, with just a few bucks to his name. Eventually, all that really mattered to him was his military training, & primal instinct for survival. He needed just the basics - light, fire, & shelter.

I'm going to try & make a replica of what got him through the tough times, & allowed him to survive the elements in comfort for the past year or so.

Also, I want the build to be useable & practical, so people other than small dolls (sorry Jack) can take it camping, etc.

 

Jack's Survival Shack

(2018 BLF DIY contest - aka, the year of the lantern)

 

 The backbone of the build (& the roof of the Survival Shack) is comprised of a solar panel measuring about 240*340mm, which will be supplying the power to several outlets in the Shack. I've never played with solar before, but was able to get a little info from a thread here at BLF to point me in the right direction (I think!).

 I started out with the panel, & a rough layout of some of the components;

 

 I got a hold of some nice composite sheeting off-cuts from work, which is basically a sandwich of two thin aluminium sheets with a plastic center. It's light, strong, & easy to work with. In fact, so easy, Jack was able to start cutting out pieces before I knew it...

 The first job was to start work on the Lantern head, which will be detachable from the shack;

 

 The Lantern head will have 9* Nichia 219A's, which should give a nice warm light. The 219's were flowed onto 20mm stars, which will each be attached by machine screws to the faceplate. Fortunately, the composite sheet allows me to self-tap the screws in, so I didn't have to thread 18 mounting holes....

 

 The lantern head will house the cells & electronics; at this point, I have attached four 18650 cell holders to the backside of the faceplate. I'll come back to the electronics & wiring later in the build.

 A slightly larger square of the composite was cut out, which will form the top of the lantern head assembly. I didn't have any C channel handy, so I made some C shape brackets out of some flat stock, which were then drilled & tapped, so as to attach the face & head plates.

 

 

 With the two main plates attached, a set of small side plates were also cut out, & the brackets were drilled & tapped. At this point, it would have been smart to mark all of these pieces, but unlike Don's build, Jack just decided to take apart everything & dump it in a pile.... So I had a Rubik's cube on my hands, trying to align all of the brackets & holes again...

 

 

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 Next up was sorting out the charging connector & control switches for the Lantern; There will be an on/off lockout switch, plus a momentary switch. The four cells in the Lantern head can be charged via the on-board micro USB charging circuit.

 

 During another raid on the scrap bin, I found some nice corrugated alloy sheet, which had a nice depth in which the switches could reside. The momentary switch is flowed onto an old XML 16mm star, and both switches are backed with an adhesive foam strip.The assembly was then attached to the side panel with machine screws.

 

  The Chassis of the solar panel will house some USB converters, which take thier power directly from the panel. These will supply power for the other components, & allow external devices such as 'phones to be charged from the Shack.

 

 

 With the main power modules & switches sorted out, Jack insulated the bases of the boards with kapton tape, prior to epoxying everything into place. The USB modules have adhesive backing foam attached, to aid in ridgidity once the plate is re-attached to the chassis.

 

 After the epoxy had set, it was time to see if the USB modules were working. The panel was outputting around 20v, but did not appear to be producing much current.

  Plugging a USB test meter into any of the modules showed the correct USB voltage, but there was not even enough current to power the backlight of the test module...

 So either I have a faulty panel, or my complete lack of knowledge in this field has come to the surface yell

 

------=========------

 

11-11-18

  With another panel on it's way, I turned the focus onto the Lantern part of the build. I wanted to keep the whole "Shack" reasonably compact, so a solid lantern body was not going to work.

 I had the idea of making the lantern body out of fabric, so it could be retracted into the Shack when packed away.

An off-white semi-transparent cloth offcut was sourced from my local friendly canvas shop, & was cut to size to form the sides of the Lantern.

I then made a frame from the composite sheet to attach the cloth to the face of the Lantern head, & fabricated the bottom rail from a length of brazing rod, which funnily enough was brazed together....

 

 

 The first attempt to join the cloth ends together didn't go too well, so another length of fabric was cut to size. It was a little windy, so Jack actually made himself useful as a paperweight, whilst trying to remove the epoxy mixing stick from his boot....

 With the second piece of fabric joined nicely, it was carefully attached to the upper frame;

 

 

 With the upper half completed, the lower rail was placed in position, & glued in. The fabric was wrapped around the rail, & super glued together.

In the last picture below, Jack is seen holding up the finished Lantern body. It appears that he's not having much luck with the super glue, & we know how hard that stuff is to get off skin....

 

 

---------==============----------

 

 

 

 

FmC
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Ambulance

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Health Insurance

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Lemme guess… while making smores, Jack caught a marshmallow on fire, shook the stick, flinging the firery marshmallow into someone’s eyes. The ambulance had to be called, and eventually a health insurance battle ensued?

That Jack… so ornery!

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You have no idea how hard it was to get Jack to return home to you. I guess he just loved playing with the sacked assistants, Jack and Loopy Smile

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.

 

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Placeholder
Smores
Ambulance
Health Insurance

Looks good already! Party

Reason is not automatic. Those who deny it cannot be conquered by it. Do not count on them. Leave them alone.
-Ayn Rand

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Smile
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Machine made? I feel a bit lonely in this category …

Edit: Just noticed you are in handmade category Sad
Anyway, good luck!

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gchart wrote:
Lemme guess… while making smores, Jack caught a marshmallow on fire, shook the stick, flinging the firery marshmallow into someone’s eyes. The ambulance had to be called, and eventually a health insurance battle ensued?

That Jack… so ornery!

Aw man, you’re just putting ideas into his head! Facepalm

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FmC, I just read your Post #2 update. I just gotta tell ya, you tell the best stories! Hat

Reason is not automatic. Those who deny it cannot be conquered by it. Do not count on them. Leave them alone.
-Ayn Rand

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DavidEF wrote:
FmC, I just read your Post #2 update. I just gotta tell ya, you tell the best stories! Hat

Jack gives me all of the material….. All I have to do is type it out Big Smile

2nd post updated – hopefully the pictures are showing today.

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Good to see everyone back on board and working hard. 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.

 

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FmC wrote:
DavidEF wrote:
FmC, I just read your Post #2 update. I just gotta tell ya, you tell the best stories! Hat

Jack gives me all of the material….. All I have to do is type it out Big Smile

2nd post updated – hopefully the pictures are showing today.


I don’t see the pictures.

Reason is not automatic. Those who deny it cannot be conquered by it. Do not count on them. Leave them alone.
-Ayn Rand

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DavidEF wrote:

I don’t see the pictures.

Pictures are all good here.

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.

 

pinkpanda3310
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I don’t see pics either. Phone or pc.

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I am getting a missing image filler, too. Sad

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Thanks folks – I’ve re-linked the pictures.

Hopefully they are visible now Thumbs Up

raccoon city
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I finally see the pics.  :BEER:

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Guess who’s back, back again?
Jack is back, tell a friend! Cool
Good luck with the builds FmC (the flashlight and the story Wink )

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Pics are good, stories good. I believe Jack is doing all the work, I really do. Are you by chance any relation to Captain H. M. “Howling Mad” Murdock? I’m noticing some familiar traits…

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FmC wrote:
After some good times & bad decisions, Jack ended up getting stranded in a remote area, ….

Tell us what really happened. Did Jack get lost in the garden after a big night and took shelter under a solar garden light? LOL

Love your stories/builds

FmC
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Sillen wrote:
Pics are good, stories good. I believe Jack is doing all the work, I really do. Are you by chance any relation to Captain H. M. “Howling Mad” Murdock? I’m noticing some familiar traits…

I’m not sure what happened to Captain Murdoch after the 80’s… I heard he immigrated somewhere Davie

pinkpanda3310 wrote:
Tell us what really happened. Did Jack get lost in the garden after a big night and took shelter under a solar garden light? LOL

Love your stories/builds

Lol – that’s probably closer to the mark…. Big Smile

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Very nice start FmC, glad that Jack is back on board on this year’s build! That composite stuff is great, I have some in orange, a leftover from a building site. It is a pity you can not get it easy.

link to djozz tests 

“I used to think that top environmental problems were biodiversity loss, ecosystem collapse and climate change. I thought that thirty years of good science could address these problems. I was wrong. The top environmental problems are selfishness, greed and apathy, and to deal with these we need a cultural and spiritual transformation. And we scientists don’t know how to do that.”   (Gus Speth)

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Thumbs Up Cool!
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Pics are good now, and everything looks like it’s coming together nicely, in spite of Jack’s help! Evil

Reason is not automatic. Those who deny it cannot be conquered by it. Do not count on them. Leave them alone.
-Ayn Rand

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People here are so devilishly clever. Scary sometimes.

Great work, keep Barbie out of the picture or Jack will never finish in time…

Dale

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Good luck with the build, Jack !

Beer

Q

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Why use 219As? I’ve never seen those emitters used in a light before. Granted, I’ve only been in the hobby for a couple years. I think they were obsolete by the time I started.

Reviewer for ThorFire, Olight, Sofirn, and Folomov.
More active on Reddit: /u/Virisenox_

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perhaps they were already on hand??

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