Volk wrote:

Wow, impressive work there!

Thanks very much.  It was really a tough job, so it's nice to have it be appreciated!

Volk wrote:

Aux lights for the car? (at least I wish it is )

Exactly.  Going on the brush-guard of my Jeep Grand Cherokee

PPtk

Chicago X wrote:

Wow - beautiful.

I don't even CARE what it is.  I want one.

Haha.. Thank you!

No need for a Jeep.

It would also make an excellent EDC torch

PPtk

Now I have to convince myself to sit down for an hour or two and finish up the circuit board layout..  Hopefully, I'll have this thing mostly put together in 2 weeks or so.  Can't wait to see the output from 240 watts worth of LEDs

When I drew this, the cad tool said it would weigh 4.01831 Pounds.  Just tossed it on a (pretty darn accurate) scale.  4.03 Pounds

Color me amazed..

Pulsar wrote:

I'm interested too. I've been contemplating what route I want to go with aux lights on my x, the majority thought is be better off with hid. What emitters you gunna run in that?

XM-L mostly.  The very center will have a couple of XP-Gs for some extra throw.

I considered HID, but I like the solid-state nature of LEDs.  I'm going to pot the entire thing in optically clear silicone.  I should be able to drop this thing off the empire state building and have it still light up after it hits the ground.

18 XM-L + 6 XP-G

Yeah.. I think it might beat out the solarforces and sky-rays

What the final assembly is planned to look like...

Ledsmoke wrote:

That is some sweet work there PilotPTK!

I love the idea.

Are you going to fit some optics to the LED's to focus them or what is your thoughts on that?

Thanks very much!  Glad you like it!

Perhaps this picture will explain the plan for the optics.

Budgeteer wrote:

Home anodizing or local shop that does it?

I hate the mess and smell of anodizing 'stuff'.. For the small cost, I have a shop do it to MIL-A-8625 Type III, Class 2 specification

PPtk

MixoMaxo wrote:

very nice project gz, hurry up! wish to see it in action

not sure why gz means - but It will probably still be 2-3 weeks before I have it fully built up.

MixoMaxo wrote:

How you made the aluminum body?

CNC Machined from a 18" x 4" x 4" billet of 6061 Aluminum

MixoMaxo wrote:

How to fit and isolate the lens? my laziness make me think to a big rectangle of plexiglas to cover all xD

I'm not sure I understand your question.  The lenses will be attached to the mounting holes on the circuit board, positioned perfectly over the LEDs on the circuit board.  On the front of the enclosure will be a piece of laser-cut Lexan with an aluminum bezel around the edge.

BetweenRides wrote:

Most awesome bike light ever!!!! Can I have one with a bar and a helmet mount option?

Ha! That would be great.  It probably weighs more than your bike though  Just the machined enclosure is a hair over 4 pounds, and that doesn't include circuit board, LEDs, lenses, screws, the lexan and aluminum bezel or the mounting brackets..  Plus, you'll need to supply it with about 20 AMPS at 12V

It would make an awesome bike light though!

BetweenRides wrote:

Yeah, you're right. Please let us know when you've got the build complete. I would love your permission to link to it over at the mtbr forums DIY Light section. I think the biggest bar light I've seen over there is 10 LEDs, but they were pretty small ones, arranged 2x5.

I'll keep this thread updated with my progress on the build.  Right now, I have to finish the circuit board layout, get PCBs fabricated, build up the parts (LED's, microcontroller, Buck-Boost sections, etc.), debug, and then physically assemble the unit.  Lots to do..

As for linking to another forum - Please feel free.  I enjoy sharing my work and ideas.

PPtk

Tony Hanna wrote:

I'll take two! One for the roof and one for the front bumper. 

Picture not showing up - but I actually have considered selling these once I have the design working and debugged..  I'll keep you informed if I decide to do that..

PPtk