Scratch-built 7x C8 reflector high-output thrower

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EasyB
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Speed4goal wrote:
Wow amazing work, who needs a tn42 when you can have this

Heh. The beam should be like a TN42 but with 4x the beam area (twice the beam width).

It does tail-stand. Big Smile I also left room on the tail cap to make a lanyard/shoulder strap hole.

djozz
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Great build and very BLF Smile

To could also carefully drill 3 holes in the lens around the center reflector and fix the lens with bolds (rubber rings under the heads) in the led base plate.

EasyB
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djozz wrote:
Great build and very BLF Smile

To could also carefully drill 3 holes in the lens around the center reflector and fix the lens with bolds (rubber rings under the heads) in the led base plate.

That’s an interesting idea, thanks.

EasyB
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OK, I got some beamshots. The location is a lake. There are small docks with benches distributed along the shore. The distance between the two I’ve chosen is about 500m. You can just make out the dock in the beamshots. Unfortunately it cooled down today and tonight so there is a bit of moisture in the air.

This is what one of the docks looks like.

I have beamshots of 4 of my throwy lights, widely distributed in candela. All photos have the same exposure settings and, at least on my computer, they look roughly what it looked like in real life.

First is an Eagle Eye X6 with dedomed XPL V6 1A with Ledil Iris TIR. It has about 95Kcd.

Next is my fresnel lens Convoy C8 conversion with dedomed XPG2. It has around 166Kcd.

Next is a larger fresnel lens light (60mm active diameter) with dedomed XPG2. It has around 310Kcd.

Next is the monster 7x C8 high output thrower with ~740Kcd.

It puts a lot of light downrange and really is in a separate league compared to my other lights.

DBSAR
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Impressive! Big Smile

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DBSAR wrote:
Impressive! Big Smile

Impessive? I’ll up that one and go super impressive. Smile

 

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.

 

pinkpanda3310
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Lux that high with a hotspot that big is just awesome Shocked Great job Beer

  

FmC
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That’s one heck of a thrower! Beer

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Whoa! Heck yea, that’ll do it!

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pinkpanda3310 wrote:
Lux that high with a hotspot that big is just awesome Shocked Great job Beer

Well said. This is what l was thinking but couldn’t put it in words. 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.

 

The Miller
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nice!
super? no hyper impressive!
dang what wall of light, no more a train of light

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Not nearly bright enough for me but I guess it would be “okay” for walking the dog or something.

Wink

EasyB
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I’ve been thinking about my next very high output light and decided upgrading the emitters in this 7xC8 light is a good route. I will replace the dedomed XPLs with sliced XHP50.2s. With 2 high drain aspire 26650s I should get around 5.5A per emitter (6V ). I just tested a sliced XHP50.2 in a C8 at 5.5A and got 3100 lumens OTF and 69Kcd, so the full light should output around 22000 lumens and do 480Kcd. Will update when I get the mod done. Cool

Jtm94
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Sounds absurd. I love it!

cu42
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Very nice. I am always interested in anything hand crafted. I have made a few flashlights for myself and helmet lights for night riding. I am always ribbed for going overkill. To me there is no such thing…

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cu42 wrote:
Very nice. I am always interested in anything hand crafted. I have made a few flashlights for myself and helmet lights for night riding. I am always ribbed for going overkill. To me there is no such thing…

I’ve repeatedly said this to peeps whenever they’ve asked why I did so much of this and that…..ya know like buying a bunch of something if it’s a great deal…………

What’s not worth doing to excess is not worth doing.”

They usually just stand there speechless. LOL

“In many things in order to truly understand the small picture you have to understand the big picture first.”

True Color Rendition (TCR)/Simplified Definition: “On a scale of 1 to 10, with 10 being the highest rating, a TCR will equate to what true colors you see in sunlight vs the same object’s colors you see when illuminated with a flashlight. The closer the two are, the higher the TCR rating will be.”

The TCR Reference Standard is the Walmart Ozark Trail OT 50L , Model No. 6103.
It has a TCR rating of ‘10’. $1.00 including batteries.

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Looks very impressive. Any chance for beamshots?

EasyB
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SKV89 wrote:
Looks very impressive. Any chance for beamshots?

I’ll take some wall beam shots to compare beam size before and after, but probably won’t get around to outdoor shots like in post #35 for awhile.

SKV89
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EasyB wrote:
SKV89 wrote:
Looks very impressive. Any chance for beamshots?

I’ll take some wall beam shots to compare beam size before and after, but probably won’t get around to outdoor shots like in post #35 for awhile.

Oh I actually didn’t see the pictures in post #35 because I was using my cell phone. Now I see it. The beam is marvelous! I wish the manufacturers would make something like that. Maybe even use XHP35 HI.

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Easy B,

 

Exceptional minds think alike, and history repeats itself...

 

When I first started this hobby 15 years ago there was a one man army named Wayne and his company Elektrolumens that pioneered the formula behind your outstanding design. CNC machined head and body lights that utilized clusters of LEDs and reflectors to achieve a massive flood wall of light with extraordinary throw character as well, the holy Grail of flashlights to have them BOTH.

 

He made his own designs and I was awestruck with the incredible performance of geometric array lights. He started off with 5,6,7 and up to 12 in one gargantuan head. Back then using NiMH batteries because LiIon had not yet evolved fully enough to supply the insane parallel current demands.

 

Wonderfully you have included active cooling, a necessity for the insane waste heat your array will make for continuous duty. I suggest going a step further and going to a liquid cooling or reverse Peltier design for even greater effeciency.

 

Standing ovation BRAVOS for your ingenuity and skills. I can't wait to see how it evolves and WOWs even the most crusty die hard of us.....

 

 

Best of LUX Smile 

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“EasyB” Now that’s thinking outside the box Beer You are gem here and I love to see people like you making their visions into reality. That is quite an accomplishment, I am very impressed.

Since you mentioned modding this Monster, you may be interested in these reflectors for maybe closer to 2 mile range. They are 2X deeper than the C8. Beer

https://www.aliexpress.com/item/1PC-NEW-HS-802-802-LED-Flashlight-Reflector-Aluminum-Smooth-SMO-Torch-Light-Cup-Dia-41/32821558396.html?spm=2114.10010108.1000014.1.6c9c3f16PQVraI&scm=1007.13338.98644.000000000000000&scm_id=1007.13338.98644.000000000000000&scm-url=1007.13338.98644.000000000000000&pvid=7e42b83e-1f21-470a-962e-46a745da84ca&_t=pvid:7e42b83e-1f21-470a-962e-46a745da84ca,scm-url:1007.13338.98644.000000000000000

https://www.aliexpress.com/item/41mm-D-x-60mm-H-SMO-Aluminum-Reflector-for-CREE-XM-L/32851870851.html?spm=2114.search0302.3.23.1b144e20yYymsq&ws_ab_test=searchweb0_0,searchweb201602_0_10130_10152_10151_10815_10814_10618_10059_10696_10084_100031_10083_10547_10624_10546_10623_10307_10548_10341_10065_10340_10068_10343_10342_308_10103_10620_10344_10325_10545_10622_10324_10621,searchweb201603_0,ppcSwitch_0&algo_pvid=2c89ac56-d1f2-42d4-b855-0106a4913ced&algo_expid=2c89ac56-d1f2-42d4-b855-0106a4913ced-3

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http://i.imgur.com/HYzQXXu.gif

Mmmkay, are you going to dare with 19x or 43x versions? LoL!

 

Cheers Smile

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EasyB
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Thanks guys. Smile

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I love circles in groups of 7 Smile

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In 2005, my insane high-performance no holds barred wall of light WITH staggering long throw was an Elektrolumens circle-of-six plus 1 center with 27mm McR reflectors for each of 7 (3W Luxeon LEDs) ....

 

NOTHING but massive HIDs or Xenon short-arc lights could come close to that discrete LED/reflector array head. It had an infinite variable adjustable dimmer pot knob for intuitive output control (and ultimate runtime preservation need be) ; the analog predecessor to NARSIL) Smile

 

BRAVO EASYB for building, and striving to go beyond, your epic creation !! Standing Ovation my friend !!

 

Smile 

 

EasyB
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Another emitter option for this light is the XHP35 HI, but I would need to add 2 more cells to make it 4s. 4 decent cells in series would drive 7 XHP35 very well with a FET driver, around 2.4A per emitter. This would make around 15000 lumens and 940Kcd.

I am giving up some throw by going to the sliced xhp50.2, but I think the beam will be great for 200m to 500m where it is more likely to be used. (Though who am I kidding, I don’t really have a use for this light Big Smile )

EasyB
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I finally got around to putting in the XHP50.2s and after just a few short bursts with some mostly charged liitokalas some of the emitters died. A connection in the XHP50.2 goes bad and half the dies go dark. I had read about this happening but I didn’t think it would happen so often. 5 out of the 7 have failed now. Pretty disappointing, but I think I have to abandon the XHP50.2s.

One option is to put in 4 sliced SST40s (2s2p configuration) and 3 sliced XHP70.2s. This should get me similar performance, around 500 Kcd and 21ish Klumens. Not sure what the beam would be like.

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Sorry about your misfortune. I hope you get something in it and get it back up and running. That had to hurt though, losing those XHP50.2’s!

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EasyB
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EasyB wrote:
One option is to put in 4 sliced SST40s (2s2p configuration) and 3 sliced XHP70.2s. This should get me similar performance, around 500 Kcd and 21ish Klumens. Not sure what the beam would be like.

Just ordered some emitters to do this. I estimate with 4300mAh aspire 26650s each 2mmx2mm die should get around 5A, or around 40A from the battery in 2s configuration. I estimate it will do around 600kcd and 22000 lumens.

EasyB
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Emitter upgrade:
I changed out the emitters for 4 sliced SST40s and 3 sliced XHP70.2s. The original 7x XPL version of this light worked well, but with all the very-high-output lights coming out my desire for power motivated me to redesign the light. 7x sliced XHP50.2 would have worked great, but when most of the XHP50.2s failed I looked for other options. I predicted the SST40 + XHP70.2 arrangement would give similar high intensity and output as the XHP50.2s, but how would the beam look? The idea was to have an intense beam center that would reach out far and provide the viewer with lots of detail of the subject/target, then the XHP70.2s would provide a wider, less bright, view of the surrounding scene.

I had never mixed different sized emitters in a light so I didn’t know quite what to expect in the beam. The beam from the XHP70.2s would have about twice the diameter as the SST40 beam. My concern was whether the XHP70.2 beam would be too dim compared to the SST40 beam. If this happened it would not really help with illuminating the surroundings far out. The output of the flashlight would still be high, but the two beams would not be working well together to illuminate the same scene. The SST40s are arranged in 2s2p configuration and the XHP70.2s are 6V. The forward voltage of the 2s2p SST40 arrangement is similar to an XHP70.2 so it should get similar current to each of the XHP70.2s (i.e. each 2×2mm die should get similar current). With this knowledge I estimated that the 4 SST40 reflectors would provide around 400kcd combined and the 3 XHP70.2 reflectors would provide around 150kcd. So the larger XHP70.2 “corona” would be around a quarter of the intensity of the beam center. I figured this was close enough to the beam center intensity to effectively illuminate the surroundings of a far away scene.

On the left is the beam of the 7x XPL original light and on the right is the new configuration. The beam center intensity in each case was adjusted to be the same at the time of the pictures and the exposure settings were the same. The 3-petal pattern in the right picture is apparent because the SST40 beams are brighter than the XHP70.2 beams. As I mentioned in the first post, the plastic lens flexes and actually causes the outer reflectors to point slightly outwards, which effectively widens the beam. The beam divergence from a single reflector is greater than the divergence angle of the reflectors, so far away the beam loses the 3 petals and becomes round.

Now for some measurements. With charged Aspire 26650s I measured 35A at the tail using a 1.6 mOhm shunt in place of the tailcap (the actual tailcap resistance is 1.0 mOhms). Using ceiling bounce I estimated 23,000 lumens at start and 20,000 lumens at 5s. I think this quick output decrease is mostly due to the battery voltage falling rather than mostly heat. Based on Mooch’s test it looks like each cell’s voltage drops by 0.2V in the first 10s. Beam intensity at ~7m was 530kcd at 5-7s. With Liitokala 5000mAh 26650s at 3.75V OC I measured 19A and 14,000 lumens.

So far I only have shined it 50 or 70 meters, and the beam looks very smooth. I’m excited to try it at 300-400m. Smile

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