I’m entering the Scratch Build contest again this year in the Hand Made category. Once again, I’m starting this thread not knowing exactly what I’ll build. But, I’m feeling like I want to try something bigger than my previous attempts. This year I’m actually in better shape as far as parts are concerned. I have some large reflectors, a few interesting emitter options, and plenty of drivers to choose from. I’m still not a fabricator. So my biggest challenge will be to come up with a host design that will be interesting and a bit unique, but still be within the scope of my very limited mechanical ability.
Here we go…
Update #1 (Sep 4, 2017)
I’m going to be using a LUM 5-90 reflector, and a de-domed SST-90 emitter, probably with a FET driver to get lots of power to the hungry, hungry Luminus LED. I don’t have anything for a host, so I thought I’d try my hand at rolling my own. Well, I mean, literally rolling a cone-shaped housing for the reflector, then joining it somehow to a piece of pipe for the cell(s). I found a website that will calculate and create the template, which one may then download as a PDF, and print in any size needed. They have templates for lots of different shapes. The one I’m using is the “cone” template, using a diameter greater than zero for the small end, so it’s more of a funnel. I’ve calculated and printed the template already. Next, I’ll need to transfer the template to a sheet of metal, and roll it up. Somehow, I’ve got to close the two edges together. I was thinking of going easy on myself, by leaving a little bit of a tab and using rivets to join it.
The LUM 5-90 I have here came from Dale. Their MOQ is 5 pieces, and he didn’t need that much, so he sold some of them and I got one. Those two paper cones are for my test fit. I got it right on the second try! Yep, it doesn’t look right with the “perspective” of the shot, but Cone #2 is the right size for my light! No big deal you say? Well, I thought it was cool.
This is the SST-90, for which I had previously made an aluminum spacer for a different project. I don’t know if the little aluminum spacer will stay for this project. Pay no attention to the large format heat sink. It certainly won’t be used here. It was just used for testing.
The side panels of these old computers are nice and flat and, I think, thin enough to roll into a cone. Alternatively, I could use this old HVAC duct changeover. What do you think?
This cheap riveting tool I’ve got may be the way I close up the cone. I might also use this to connect the cone to the battery tube, if I can figure out how to do so.
That’s it for now! Slow going again this year. :weary: But, hopefully I can pick up steam a little better than last year and end up with a nice flashlight that I can be proud to have designed myself and built from scratch!