Maximum sustainable lumens? (build)

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pinkpanda3310
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Maximum sustainable lumens? (build)

A while ago I asked for help with shipping and DavidEF was kind enough to lend a hand. I appreciated it so I offered my services in return. Shortly after doing so the ebay seller I was trying to buy from contacted me and said they could ship direct to me. I didn’t want to renege on my deal with DavidEF and what he wanted kind of lined up with something I wanted to do anyway but hadn’t got around to it yet. So we agreed on a little bird price (cheap cheap).

From memory the goal was “an srk that can sustain 6k lumens from 4* sst-40 (or direct drive without thermal kick-in until the batteries run down)”. Now I have my reservations as to whether this is possible. I looked up other lights that sustain that kind of power and they are pretty much all actively cooled lights. Be that as it may I won’t let it stand in the way of this build Evil

I don’t have an srk but I do have a Trustfire df009 which has a nice 4* 18650 body. The battery setup is 2s2p but for some reason I had it in my head that it was 4s. DavidEF will supply the electrical gizzards and I have a reflector on hand that’s suitable but doesn’t fit the df009 head so I need to conjure up some kind of custom head.

Side note – just recently Dale mentioned his 458 Ham’r which I had to revisit. Kind of similar idea – srk style with custom head.

I drew on the power of the gods to rise above the chicken scratches that I normally do Crown

Start with one big lump of aluminium and hope and pray it doesn’t slip in the chuck Sick



To make sure the head was bored to the correct depth to suit the reflector I had to make up some centering rings and do a test fit. These were a bit of a pita so I only made 2 of them to get me past this point. Later I try to make them again… and again…. you’ll see Wink

Phase 1 complete. More to come tomorrow Big Smile

Dougdimadome
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As someone who enjoys seeing things get built or repaired and trying to get a degree in electrical engineering, how did you get all the skills and knowledge to do everything you are doing in the photos?

Relampago
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Nice work, looking forward to the incoming phases.

“Electricity is really just organized lightning”
― George Carlin

pinkpanda3310
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Dougdimadome wrote:
As someone who enjoys seeing things get built or repaired and trying to get a degree in electrical engineering, how did you get all the skills and knowledge to do everything you are doing in the photos?

I am very much like you, I like the creation of stuff. I took the plunge a few years back. I screwed up a wad of cash and threw it at a lathe. Then spent lots of time learning hands on and internet searching. I even asked here on blf .

Machining is a wide subject with lots to learn and there is usually more than one way to achieve something. There are numerous other guys here on blf with lathes and even 1-2 with CNC machines. I am just a hobbyist.

pinkpanda3310
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Next I made the bezel

Release the bezel from the chuck and mount the head again with bezel in place ready for shaping

To mount the head so I could work the other end of it I had to make a mandrel.

Yokiamy
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Great project, is it basically a beefed up Q8 with SSt40?

Great machining skills and pics as well Thumbs Up

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Nice pp. what is the reflector / glass or are they srk?

you’ve definitely got the hang of that lathe.. Thumbs Up

sorry all images down
thanks photobucket

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Subscribed with interest in this project.

pinkpanda3310
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Yokiamy wrote:
Great project, is it basically a beefed up Q8 with SSt40?

Great machining skills and pics as well Thumbs Up


I guess you could think of it as a beefed up Q8, though this reflector might have a bit more throw. Thanks mate Beer

lostheplot wrote:
Nice pp. what is the reflector / glass or are they srk?

you’ve definitely got the hang of that lathe.. Thumbs Up


The reflector is bigger than srk. It’s from kaidomain and the lens is from banggood . I’m glad I stepped up in lathe size. This one suits me better Smile Thanks mate Beer

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Orsm machining pp. What driver are you using?

 

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

                      "My man mousehole needs one too"

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pinkpanda3310
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I won’t be using any driver Davie DavidEF will is making the stuffing Big Smile We talked about a LD-M2 so I have made allowance for that to be fitted.

pinkpanda3310
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Milling out a flat spot for the switch was a challenge.

It looks good in the pics above but in reality I didn’t have the setup done perfect and didn’t realize because I couldn’t see well enough. The next 2 pics are the actual view angles I had.

As a result the milling was not central. I don’t think the part slipped (which was possible because of the way I set it up) , I think it was the initial alignment of the setup.

I tried to make it right but again I couldn’t see much so it’s still not perfect Facepalm I moved onto cutting out a hole for the switch. That also didn’t turn out as good as I hoped. I went a fraction too deep and cut into the internal threads Facepalm This is not such a big deal since it will be covered but I still didn’t like making the mistake. People make mistakes but when they come one after the other… Angry

I didn’t fit the switch assembly until I was pretty much done with the rest of it. When I did fit it… yup I had issue with it Tired

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This looks amazing. Please consider making more and selling for profit if it’s successful. Btw the Imalent DX80 and the Olight X9R can sustain those lumens and are not actively cooled. But they are much larger.

pinkpanda3310
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SKV89 wrote:
This looks amazing. Please consider making more and sell for profit  ...and therein lies the rub.  Manual machining is not budget machining nor is shipping from Perth Australia 

 

Thanks for the positive comment though.  For some reason I thought both of those lights were actively cooled.  However they do both have thermal ramping.   I wonder what lumens they can actually hold after thermal has kicked in?

 

SKV89
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7 to 8k lumens fir the DX80 and 6.5K lumens for the Olight

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The build looks awesome mate!
Its good to see some scratch made lights and lathe work back on BLF Big Smile

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Could you measure the base of the reflector for me?

Looking good so far! That button assembly looks good!

pinkpanda3310
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SKV89 wrote:
7 to 8k lumens fir the DX80 and 6.5K lumens for the Olight

That sounds promising. We might hit the target with this build Party
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everydaysurvivalgear wrote:
The build looks awesome mate!
Its good to see some scratch made lights and lathe work back on BLF Big Smile

It’s not 100% scratch made but I agree, it’s always good to see pics of lights in the making on blf Beer
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thijsco19 wrote:
Could you measure the base of the reflector for me?

Looking good so far! That button assembly looks good!


Lucky for you I didn’t get to the post office on Friday to send it to DavidEF.
thijsco19
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Thank you! That’s even better! (didn’t dare to ask you to make such drawing Innocent )

pinkpanda3310
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I don’t know what you need the measurement for but just one dimension usually isn’t enough to work with.

pinkpanda3310
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One of the requests was a tripod moutning point. I wasn’t sure how I was going to do this as I figured I would be machining it from scratch (denoted by the green plate at the base of the 3D pic in OP ). After some head scratching I got an idea. I have a couple of gopro style action cams. They come with more accessories than I need /use. I picked out the one with the deepest hole. In the new host it is a press fit with some epoxy to help hold it.

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Threads like these are my favorite. Keep up the good work bud! Looking forward to more updates.

Sometimes being a newb is the best part of a hobbie

pinkpanda3310
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Beer Thanks Redlyne

With the head pretty much finished I pressed the switch into place but had to remove it because it seized up when i pressed it in. The switch is made of titanium but the tolerances between the 2 parts were tight enough that the pressure of being pressed into the aluminium compressed the outer ring and gripped the button. It took me ages to work out which part was actually rubbing and I fitted and refitted too many times. Needless to say it was a real PITA Tired

Centering rings. As noted above i don’t have the size needed and figured it would be faster to make some than wait for a delivery which would be a minimum 2 weeks.

This resin was not strong enough

This plastic was not heat resistant enough

I didn’t get many pictures but this circiut board was mounted to the lathe with double sided tape which wasn’t up to the task.

I tried a piece of carbon rod but the direction the fibre runs makes it very weak for this application. To the point it could not be machined.

I made a bar of 2 part epoxy putty. I was able to shape this stuff but it feels kinda fragile.

Not satisfied I revisited the circiut board idea with a better way to mount it. I had to trim the screw head to get the shape i needed on the board.

I’ll send David both sets. They’re not pretty but they’re functional

pinkpanda3310
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Just a few pics of the finished host

Without the batteries installed it’s front heavy. With batteries not so much. Extended usage may feel front heavy

It’s somewhere close to my design drawing Innocent

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For some reason, I’m just now seeing this thread. Good work! I’m looking forward to seeing the finished light! Innocent

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pinkpanda3310
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I figured you were just busy or something Smile

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Wow! Photon blaster.

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UH-MAY-ZING!!

A thing of beauty!

SUPER SEXY!!

Awe inspiring!!

NEED!!

Caleb
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We all have Q8s. I bet if someone produced replacement heads like this for that for the Q8 demand could be in the thousands.

pinkpanda3310
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Caleb wrote:
We all have Q8s. I bet if someone produced replacement heads like this for that for the Q8 demand could be in the thousands.

Edit….. I probably shouldn’t dob him in like that Oops
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Caleb wrote:
We all have Q8s. I bet if someone produced replacement heads like this for that for the Q8 demand could be in the thousands.

We all have C8 (18650 version). I have invested a lot in C8TT, but demand is near 10pcs/year.

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