What to do with a 65mm x 63mm Deep Reflector ? - Turn it into a cut down Maglite Thrower of course!

What can I do with this Deep reflector? It doesn't seem to be the right size for anything I have. I just don't know what kind of light I can make with it?Wink

kai1

I figure it should be good for a "thrower", but I don't know yet which emitter. I think I know the host, but it's a project to think about, as I still have two incomplete projects in the works.

So...... Which emitter? what type of host? Guarantee the batteries will be NiMH, but possible I should look at making it so an 18650 or 26650 or some other type of Li (I don't know anything about Li), could be used if the end user preferred.

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So I got some time to do a little something with this light. I got the reflector in the mail today, from Kaidomain.

Here's a video of how I put the reflector into the Maglite head, using Photographic components.

I used a 46mm to 49mm adaptor inside the bezel. It centers the rest into the bezel. That attaches to a 49mm to 58mm adaptor from the outside and makes a sandwich out of the front lip of the bezel. Then I screw on a 58mm lens hood and the reflector goes into that.

There's some issues with the front of the reflector, but I will figure something out. It was all guess work again, as I ordered components by guessing. Most of the guesses were right, so I don't feel too bad about it.

I have a bunch of projects now thanks to Chicago X and I will bounce around here and there, working on them as I like.

That's all for now......

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How about for a stubby, single XML thrower powered by a 26650 ?

well, you could sell or trade it to me Sealed

I have a light shaped like this (but super cheap)

http://clydearmory.com/streamlight-waypoint-led-flashlight.html

The lens is ~67.8mm, so if that doesn't drop in it won't be hard to make it fit. I haven't found a reflector that width despite a whole lot of searching. DX has sst-90 that's too big and sst-50 that is a bit small. I had just about settled on making a plate for the sst-50 one...

anyway, that looks like a big emitter hole.

maybe even as big as these? I have one of the domed ones if you want measurements.

http://www.dealextreme.com/p/10w-led-emitter-11v-12v-500-lumens-white-6500k-5876

http://www.dealextreme.com/p/10w-7000k-700lm-white-led-emitter-metal-plate-9-11v-65692

http://www.dealextreme.com/p/10w-750lm-led-emitter-metal-plate-white-42829

Use a 2D Maglite... but it won't fit the reflector. Well, not until the Maglite is modded. Here's a crude drawing of the proposed change to the head, to accept the reflector.

draw1

I have used this design once before, to make one of the first Maglite HID lights. I needed the large hood for the HID bulb. Of course that was back in the stone ages, but the principle works here and it allows for a 65x63mm reflector to work in a Maglite and still have adjustment for flood to throw.

This will be a cut down Mag. I will be using 3AA Eneloops and I will be cutting down the body, as well as making a battery holder for the Eneloops. I plan on making it all so that Li-ion batteries could be used, specifically one "C" sized or one "D" sized Li-ion battery in place of the 3AA Holder. This way maybe someone will want it, since Li-Ion are so popular.

So.....

The build log will include:

  • Modifying the Head to accept a 65x63mm reflector
  • Shortening the body to hold 3AA or 1 Li-ion battery
  • Shortening the end cap spring
  • Modding the switch for less resistance
  • Installing a heat sink
  • Adding an XM-L Emitter on an 8mm star and a custom pedestal, so that the reflector can move up & down around it, for changing the beam.

That's about all for now. I do not have any of the parts yet. The reflector is the only thing coming from overseas. The rest of the parts come from sellers in the US, so they will come in before the reflector does. That means this is another long wait build.

Since I want this to be a "stubby" I need a good holder for AA batteries.

So... I need to make one myself.

Here's a teaser

b1

I have gotten the plastic ends cut and I still need a lot of work on it, but you can get a feel for it.

Sio, I took plastic rod stock and cut a couple slices off it. Then I used a 5/8" Forstner bit to make the seats for the batteries. I drilled a center hole and used #8x32 threaded rod to hold the holder together. I cut out copper pads for all the contacts and now it's all together. Here's a couple photos.

ba11

It's not pretty, but it functions for what it needs to do. All the copper contacts are in place.

ba12

Left is the ground, Right is the Positive. I had to keep the rod isolated, so I used a plastic nut on top and made a copper outer covering for the nut. That way the positive terminal does not touch the center rod.

ba13

The assembled battery holder. The bottom nut is a brass one, but I will expand the spring so it touches the copper base instead of the brass nut. Unscrew the brass nut, change bartteries, screw it down again and off you go.

I will not be making any of these. Parts like this need to be done on a lathe, drill press and end mill. My hack job works, but the amount of labor and the poor end result is not something I ever want to do again. From now on I will just buy the cheap chinese (yes chinese) 3aa & 3aaa holders. The hell with resistance, it's not enough resistance to matter anyhow. This was a chore to do and it's not precise enough to be dependable. Not worth the experience.

Those expensive ones on CPF? They're worth it, but way to much for my budget. There's some things that just have to be bought from china, if you're on a budget....

Carry on

whoopee!

imho, making it adjustable is 10x better than not...

Very creative use of off-the-shelf parts. The utilization of photo equipment guarantees a minimum level of machining not found in, for example, plumbing parts.

I look forward to seeing this super-thrower in action.

Shall I prepare one of Monsieur's usuals ?

Not just yet.

I will have to wait till I get the reflector, since the OAL of the finished head will determine reflector placement and therefore heatsink placement. I am not sure of how I want to do the heatsink yet.

Sounds like a plan.

Have you decided on a driver yet, or are you going DD on this one ?

Going DD on it. Don't want anything in the path of the emitter.Wink

New video in the first post.

New pictures in Post #4

Battery Holder is finished. Go to Post #4

Battery holder looks great.

I changed up the video, to show how the reflector finally went into the completed head. I changed it in the first post, but I will add it here too.

Very nice use of the photo parts !

I wonder if a polarizing filter would be useful in reducing backscatter in high-lumen thrower applications......

Ingenious! What a great idea, Justin! Where did you order all the adapters?

Ebay

I just decide on the mm I need and do an ebay search for them. Example is: I want a 49mm to 58mm adapter. That would be a "step up" adapter. Going from 49mm (male "to lens" threads) to 58mm (female "for filter" threads). I would probably search for "49mm up adapter". It gives more hits than being totally specific, since so many vendors write it so many ways. Then I just get the cheapest one with free shipping. I do not pay shipping any more on ebay.

Step up adapters go from smaller male lens thread diameter UP to a larger diameter female thread for a filter. (49mm to 58mm).

Step down adapters go from a larger male lens thread diameter DOWN to a smaller diameter female thread for a filter. (58mm to 49mm).

The first number is Always the Male thread diameter. The Second number is Always the Female thread diameter.

I wonder what effect the UV filters I am using do? They are supposed to block UV light (well at least cut it down some), so how is that affecting that emitter?

Don't know, don't care either.Wink

It's a cheap way to make a lens for a light.

Awesome work Old-Lumens, will be watching this thread for updates!