Old Lumens Contest 2020 - Hand-made light category

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Scallywag
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Old Lumens Contest 2020 - Hand-made light category

This is my contest thread for the 8th Old Lumens Competition!

When my build is complete, I will post completed images in the top section of this post.

 

So, the idea for this light has been floating around in my head for a long time. However, until this year I didn’t own the necessary tools to accomplish the build. I still might not, but I think I do at this point, so here we go.

So, the plan is this:

Brass/copper pipe and fixtures. A ¾” pipe has an internal diameter nearly identical to that of a Convoy S2+. That’s the easy part. The hard part is going to be getting a shelf or pill for the head of the light. I’m not sure how I’m going to tackle that yet. I’ve got some ideas about brass washers and stuff, we’ll see how it goes.

Okay. Hardware store.

  • Wow, brass isn’t cheap.
  • 2” long ¾” brass “threaded male adapter nipple fitting”
    • I also bought a 4" version but it won't be getting used.
  • A pair of ¾” threaded male hose X FIP adapter fitting (¾” MHT x ¾” FIP)
  • A pair of ¾” FHT x ¼” compression hose swivel adapters

That’s the hardware. Pre-built flashlight parts that I plan to use, in accordance with the rules:

  • Switch, switch board, and switch boot
  • Going with a 20mm board for fitment reasons. Undecided on actual switch type - the MTN board will have a fwd clicky on it, but I might swap an Omten 1288
    • Collectively, “switch assembly”
  • Reflector or TIR optic (I’m undecided)
    • If reflector, it’ll be a spare from a Convoy S2+ that I built into a triple for a friend
    • If TIR, it’ll be 45 degree pebbled from Fasttech
    • Either one will probably require filing down to fit
  • LED on MCPCB. I’m not 100% sure what I’ll use yet. Will be on 16mm MCPCB. Possibles below:
    • Nichia 219B sw45k R9080 D220
    • Luxeon V 4000K
    • LH351D 90+ CRI in 4000K
  • Driver: I was considering a spare Convoy 6xAMC7135 driver I had, but I think I’ll get a 20mm 8x7135 from Convoy with guppydrv.

I hope to fully document everything I do: tools used, methods devised, attempts made and failures failed! Also, please feel free to ask any questions you may have.

 

Also, I would like to mention the inspirations for this build. CRX of course, with things like the Brass Knucklehead (1, 2, and 3) and Big Brass Nutz builds. Also, credit to everydaysurvivalgear's EDSG 5th Annual BLF / Old Lumens Scratch Made Light Contest (Handmade) Pipe Dream.

Old Lumens Contest 2020 - Hand-made light category

ZL SC62(w) | Jaxman E2L XP-G2 5A | Purple S2+ XPL-HI U6-3A | D4 w/ Luxeon V | RRT-01 | Purple FW3A, 4000K SST20 | Baton S1
Boruit D10 w/ Quadrupel Fet+1/Anduril | EagTac D25C Ti | DQG Slim AA Ti | Jaxman E3 | UF-T1 by CRX | Olight S15 Ti | Nitecore EX11.2
L6 XHP70.2 P2 4000K FET+7135 | Jaxman M8 | MF02 | Jaxman Z1 CULNM1.TG | Blue S2+ w/ ML Special | Thrunite T10Tv2
Supfire M6 3xXHP50.2, Sofirn C8F, Unfinished: Sofirn SP70, IYP07/Tool AAA hot-rods, Jetbeam E3S
Others: Nitecore EC23 | Nebo Twyst | Streamlight ProTac 1AA | TerraLux LightStar 100

Edited by: Scallywag on 08/22/2020 - 01:00
Scallywag
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So, here’s the stuff.

Brass parts from the hardware store (Lowe’s, if it matters).

Probably going with the TIR. It looks like it basically fits. This is a 45 degree TIR from fasttech – I got a 5-pack to try in my Boruit D10.

Here you can see it with the hose adapter closed over the top. It has some sort of rubber sealer o-ring thing, too. Sweet.

As you can see below, it looks like the reflector would require a bit of sanding:

Some mock-up pictures of things screwed together mostly. There’s no internals – just the TIR sitting in one end and a switch boot in the other.


And a size comparison to some well-known lights (Convoy S2+ and Emisar D4):

Now I wait for parts! Currently I don’t have the driver, MCPCB (though I have all the LED options I mentioned), or switch. When they come in, I’ll try to figure out how to get them mounted in the host!

Tools I expect to use:
Soldering iron, clearly. My hotplate maybe if it’s allowed – if not, I won’t use it except to reflow my LEDs.
Hacksaw maybe.
Drill maybe.
I will document what and how I modify things, and photograph to the best of my ability!

Another challenge: I’ve noticed that, since I didn’t actually use a 3/4” pipe but instead a threaded nipple adapter, the internal diameter of the main tube is larger than I’d hoped for. Since I considering using an existing battery adapter tube cheating (even if someone says its not), I’ll at some point find something to improve the fit, but it won’t be from a flashlight.

Old Lumens Contest 2020 - Hand-made light category

ZL SC62(w) | Jaxman E2L XP-G2 5A | Purple S2+ XPL-HI U6-3A | D4 w/ Luxeon V | RRT-01 | Purple FW3A, 4000K SST20 | Baton S1
Boruit D10 w/ Quadrupel Fet+1/Anduril | EagTac D25C Ti | DQG Slim AA Ti | Jaxman E3 | UF-T1 by CRX | Olight S15 Ti | Nitecore EX11.2
L6 XHP70.2 P2 4000K FET+7135 | Jaxman M8 | MF02 | Jaxman Z1 CULNM1.TG | Blue S2+ w/ ML Special | Thrunite T10Tv2
Supfire M6 3xXHP50.2, Sofirn C8F, Unfinished: Sofirn SP70, IYP07/Tool AAA hot-rods, Jetbeam E3S
Others: Nitecore EC23 | Nebo Twyst | Streamlight ProTac 1AA | TerraLux LightStar 100

grin
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Good luck with your build Thumbs Up

Maybe a copper sleave would work

Scallywag
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grin wrote:
Good luck with your build Thumbs Up

Maybe a copper sleave would work


Yeah – so my backup plan is just to cut a rectangle of cardboard. But I’m hoping to figure something out with a sleeve of some sort – maybe pipe or tubing, hopefully. I mean I’ve heard of people wrapping tape around cells to eliminate rattle, so it shouldn’t be a big issue. I’m just not going to use the plastic battery sleeve I have for 18650 to 21700 (came with my C8F) because that feels like cheating, even if somebody said it technically wasn’t.

Old Lumens Contest 2020 - Hand-made light category

ZL SC62(w) | Jaxman E2L XP-G2 5A | Purple S2+ XPL-HI U6-3A | D4 w/ Luxeon V | RRT-01 | Purple FW3A, 4000K SST20 | Baton S1
Boruit D10 w/ Quadrupel Fet+1/Anduril | EagTac D25C Ti | DQG Slim AA Ti | Jaxman E3 | UF-T1 by CRX | Olight S15 Ti | Nitecore EX11.2
L6 XHP70.2 P2 4000K FET+7135 | Jaxman M8 | MF02 | Jaxman Z1 CULNM1.TG | Blue S2+ w/ ML Special | Thrunite T10Tv2
Supfire M6 3xXHP50.2, Sofirn C8F, Unfinished: Sofirn SP70, IYP07/Tool AAA hot-rods, Jetbeam E3S
Others: Nitecore EC23 | Nebo Twyst | Streamlight ProTac 1AA | TerraLux LightStar 100

grin
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Copper and brass is easy to solder with electronics solder just use your hot plate to preheat. Joint has to be shiny clean, a small dob of solder on the tip helps heat tranfer much quicker.

Just a tip
tube is measured outside diameter
pipe is measured inside diameter

MascaratumB
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Looking forward to see where this drives us Wink
Good luck!!!

[REVIEWS] ACEBEAM: H20 / TK16 // AMUTORCH: S3 / S3 vs 219c / AM30 / AX1 / VG10 // BLITZWOLF: BW-ET1 // BRINYTE: T28 / PT18pro / PT28 // DQG: AA Slim Ti // FIREFLIES: ROT66 GEN II // HC-LIGHTS: SS AAA // KLARUS: XT1C // LIVARNOLUX: 314791 // LUMINTOP: Tool AA V2.0 + Tool 25 // NITEFOX: UT20 / ES10K / K3 // ODEPRO: KL52 / B108 // OLIGHT: M2R Warrior // ON THE ROAD: M1 / i3 / M3 Pro / 311 / Z821 / i5 // ROVYVON: A2 + A5R / E300S / A8 / A23 / E200u // SKILHUNT: M150 / M200 // SOFIRN: SF14 + SP10A / SP32A / SP10B // WUBEN: TO10R / E05 / T70 / E10 / TO50R / E19 / E12R // XTAR: PB2 Charger // Mods: 1 / 2 // TIR: 1 / 2 // Others: Biscotti 3 + 1*7135 / Triple TIR w/ XP-G2 /// My Collection /// My Review's Blog (PT) /// OL Contest 2019 /// GIVEAWAY: 1 / 2

Scallywag
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Y’all gonna have to wait a bit on this one. While the mountain order should arrive this week, my daughter should be arriving (being born, that is) today (27th).

So if I don’t circle back around to finishing this one in time, it’s for a good reason Wink

Old Lumens Contest 2020 - Hand-made light category

ZL SC62(w) | Jaxman E2L XP-G2 5A | Purple S2+ XPL-HI U6-3A | D4 w/ Luxeon V | RRT-01 | Purple FW3A, 4000K SST20 | Baton S1
Boruit D10 w/ Quadrupel Fet+1/Anduril | EagTac D25C Ti | DQG Slim AA Ti | Jaxman E3 | UF-T1 by CRX | Olight S15 Ti | Nitecore EX11.2
L6 XHP70.2 P2 4000K FET+7135 | Jaxman M8 | MF02 | Jaxman Z1 CULNM1.TG | Blue S2+ w/ ML Special | Thrunite T10Tv2
Supfire M6 3xXHP50.2, Sofirn C8F, Unfinished: Sofirn SP70, IYP07/Tool AAA hot-rods, Jetbeam E3S
Others: Nitecore EC23 | Nebo Twyst | Streamlight ProTac 1AA | TerraLux LightStar 100

MtnDon
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Congrats on the new delivery! Your daughter!

MascaratumB
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Scallywag wrote:
Y’all gonna have to wait a bit on this one. While the mountain order should arrive this week, my daughter should be arriving (being born, that is) today (27th).

So if I don’t circle back around to finishing this one in time, it’s for a good reason Wink


Congratulations Party
Seems like you’ll have bigger “mods” to do from now on: modding life Big Smile
Wish her and the rest of the family health and a good life Blushing

[REVIEWS] ACEBEAM: H20 / TK16 // AMUTORCH: S3 / S3 vs 219c / AM30 / AX1 / VG10 // BLITZWOLF: BW-ET1 // BRINYTE: T28 / PT18pro / PT28 // DQG: AA Slim Ti // FIREFLIES: ROT66 GEN II // HC-LIGHTS: SS AAA // KLARUS: XT1C // LIVARNOLUX: 314791 // LUMINTOP: Tool AA V2.0 + Tool 25 // NITEFOX: UT20 / ES10K / K3 // ODEPRO: KL52 / B108 // OLIGHT: M2R Warrior // ON THE ROAD: M1 / i3 / M3 Pro / 311 / Z821 / i5 // ROVYVON: A2 + A5R / E300S / A8 / A23 / E200u // SKILHUNT: M150 / M200 // SOFIRN: SF14 + SP10A / SP32A / SP10B // WUBEN: TO10R / E05 / T70 / E10 / TO50R / E19 / E12R // XTAR: PB2 Charger // Mods: 1 / 2 // TIR: 1 / 2 // Others: Biscotti 3 + 1*7135 / Triple TIR w/ XP-G2 /// My Collection /// My Review's Blog (PT) /// OL Contest 2019 /// GIVEAWAY: 1 / 2

ReManG
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This is looking great so far, can’t wait to see the end product.

As for the battery rattle, maybe put a cell in a plastic bag and spray foam it in place, then when the spray foam sets, the baggie can be trimmed with the foam on the ends and will create a sleeve for the battery. The baggie should let you slide the battery out as well, maybe put some petroleum jelly on the battery inside the baggie first.

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Artiet59
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Congrats on the birth of your daughter! amazing news! Also, that “mockup” looks sick man, makes me consider heading to lowes and trying this one myself. Very inspiring! Im new to this, so I am trying to take it all in, especially the electronics aspect. The only part I have a little understanding of is the fabricobbling..

NeutralFan
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Congrats Scallywag! Daughters are very special. Mine went away to college this year and I miss her dearly. But she’s doing well and I’m happy for her. And she remembered to bring her flashlight: Father Daughter Flashlight.

I’d rather use my flashlight around the house than turn on the lights.

CNCman
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Great start Thumbs Up Congratulations on your new family Smile

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

Never give up, Never surrender. Make someone Smile today.

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That mock up looks cool as is Thumbs Up