7th annual Old Lumens Flashlight Modders & Builders Challenge (EDSG hand Made)

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everydaysurvivalgear
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7th annual Old Lumens Flashlight Modders & Builders Challenge (EDSG hand Made)

Ayyy just when ya thought i was out Silly

Well it looks like i am yet to learn my lesson and i am back for more pain lol.

I have been on the fence about my build for ages as Christmas time is really hectic. I was planing on 2 builds this year but i doubt i will have time so i will aim for one for now.

My material so far.

  • I have some triple SST-20 boards and optics
  • Basic driver.
  • Copper plates 100/100mm
  • Wood- Tasmanian oak
  • Aluminum plate and round stock if needed or for 2nd light maybe?
  • Clicky switch
  • USB charger

My main problem is cutting straight as simple as it sounds its not. I bought a mitre box but not the saw because that is how much i know about wood work. The light will have a wood frame and copper front and back if i can size it right lol. Ah yea i bought some brass screws for a nice touch lol.

I was trying some fancy ends on my wood like dove tail joint but i think i need a chisel for that.

The only chisel i know is cold chisel sigh!

22/1
Well i tried some fancy joints and no go even a Mitre joint is hard to get it even so for now i will stick with a butt joint.

I got me some thinner wood as the other wood is about 1.5mm thick and this stuff is 800mm i think.

I got a new saw that fits in the mitre box lol

Test fit

Honestly i tried so many joints lol I can’t get it right and i don’t have that much time to learn but i would like to learn.

Majority of my time was spent wasted trying to make joints work lol.

Update 23/1

I hand sanded the box and rounded the edges by hand. Not enough stock to belt sand safely.

For thermal reason the copper is almost 1mm thick and trying to saw it size was not working so i sheared of stock.

Test fitting the top

13/2
Back at it!

I have now fully sanded the box added some soft edges.

I was to scared to sand the copper by machine because the copper is soft it may deform. The copper is in between for thickness i should have either gone thinner or thicker and just made a choice lol. I think its 0.8mm thick.

shaped the copper by hand

Expensive lol

I gave the wood its first coat using this stuff

14/2
I done a second coat of the stain stuff


21/2

Ah thank fudge for the auto hole punchers lol

Edited by: everydaysurvivalgear on 02/20/2020 - 13:56
MascaratumB
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Hey, welcome to the contest and good luck with the build!

Don’t forget to announce it on the main thread Wink
http://budgetlightforum.com/node/70105

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MRsDNF
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All the best Chris. Hope you have more luck with fingers than I do. 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.

 

CRX
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Asian8640
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I will confirm that it is ideal to use a VERY SHARP and well-planed chisel for any joints you want to make with wood. I’m terrible at it. Take it from the guy that taught me how to use chisels. He told me to avoid using chisels because I’m so clumsy. I rather keep my fingers :D. Good luck with the build. You’re doing fine. I suggest you use a wooden brace and 45-degree angle cuts to fit your wooden frame together. You already have a miter box, which should really help with cutting straight. It won’t be as pretty as a dove-tail joint, but it should be much easier to do with what you have.

everydaysurvivalgear
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Thanks lads!

everydaysurvivalgear
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Asian8640 wrote:
I will confirm that it is ideal to use a VERY SHARP and well-planed chisel for any joints you want to make with wood. I’m terrible at it. Take it from the guy that taught me how to use chisels. He told me to avoid using chisels because I’m so clumsy. I rather keep my fingers :D. Good luck with the build. You’re doing fine. I suggest you use a wooden brace and 45-degree angle cuts to fit your wooden frame together. You already have a miter box, which should really help with cutting straight. It won’t be as pretty as a dove-tail joint, but it should be much easier to do with what you have.

Thanks for the extra info i will buy a mitre saw, Last time my straight edge worked but i had more room to move on bench. Even if i do a butt joint like last time i have a belt sander i can use to round the edges. I thought fancy edges would look nice.

Asian8640
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everydaysurvivalgear wrote:
Asian8640 wrote:
I will confirm that it is ideal to use a VERY SHARP and well-planed chisel for any joints you want to make with wood. I’m terrible at it. Take it from the guy that taught me how to use chisels. He told me to avoid using chisels because I’m so clumsy. I rather keep my fingers :D. Good luck with the build. You’re doing fine. I suggest you use a wooden brace and 45-degree angle cuts to fit your wooden frame together. You already have a miter box, which should really help with cutting straight. It won’t be as pretty as a dove-tail joint, but it should be much easier to do with what you have.

Thanks for the extra info i will buy a mitre saw, Last time my straight edge worked but i had more room to move on bench. Even if i do a butt joint like last time i have a belt sander i can use to round the edges. I thought fancy edges would look nice.

Careful. I don’t think belt sander is on the list of approved power tools uou can use for the hand-made section.

CRX
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It is on the list of acceptable tools but we do prefer good old elbow grease for hand made Big Smile

Asian8640
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CRX wrote:
It is on the list of acceptable tools but we do prefer good old elbow grease for hand made Big Smile

Thanks for the correction Big Smile

pinkpanda3310
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How did I miss this one? Good to see you entering again EDSG Thumbs Up

everydaysurvivalgear
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pinkpanda3310 wrote:
How did I miss this one? Good to see you entering again EDSG Thumbs Up

Because like usual i am bloody late lol!

everydaysurvivalgear
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A few minor updates.

MRsDNF
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Looking real good Chris. Beer

 

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.

 

MtnDon
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Good to see more progress. Thumbs Up

everydaysurvivalgear
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A few more updates.