Great stuff, Enderman :+1: :+1: :+1: :+1: :+1:
With the pump overheating, why don’t you use shorter tubing? For such a small and low power emitter it is an overkill. Lowering its resistance would relieve the stress on the poor pump. Or fabbing a metal mount that would act as a heatsink /passive cooling. You have lots of metal that could disperse the heat. Another possible solution could be using the same tubing wrapped around the motor to cool down the pump as well. Just my thoughts.
BTW this project is awesome!!!
Thank you! More beam shots hopefully coming tonight!
Thanks!
You’re right, in fact for the synios LEDs I could probably get away with using just two heatpipes or simply attaching the LED directly to the aluminum spider without any additional cooling.
However, I do want to have the flexibility of using a black flat or possibly the CFT90 in the future, and those 100% need the overkill cooling in order to not overheat.
I’m afraid to kink the tubing by wrapping it so tightly around the motor, there are special motor cooling coils for RC boats I could use if I wanted but the easiest solution is to just heatsink the pump to the aluminum body using a half-circle cut into an aluminum block, which I just machined today 
Lightbringer actually suggested I put multiple tubing runs in parallel for reduced flow restriction with the same amount of cooling, maybe in a future prototype I can do that.
For now I need to keep things simple, there is almost no room left inside 
Since the pump still has a high flow rate even with all the tubing, I think I will be fine simply adding a thermal path from the pump to the body.
BUILD PROCESS - AR lens and outdoor beamshots
The 3mm thick acrylic lens from flashlightlens.com is perfect, and is well secured with 6 screws around the front.
It looks like this in person too, almost invisible when it is on the flashlight.
BEAMSHOTS!
This time I swapped the LED out to a black flat, making it much easier to focus into a spot, although it is still not perfectly focused for max lux.
The distance to the trees is 400m.
No pics of this, but compared to the old OptoFire it has a noticeably brighter spot, while also being much larger.
The brightness of the beam is fairly similar, however the SyniosBeam has a much thicker beam due to the reflector diameter.
Would you say the hotspot on the trees is maybe about 8’ to 10’ in diameter? It looks very intense! But this is the Black Flat, right? So not able to compare to last nights shots. I don’t remember Lumens Specs for the both of them?
About 10ft I would guess, possibly more.
This is the black flat yes.
Black Flat: ~900lm, ~260cd/mm^2 (today)
Synios DMLN: ~200lm, ~310cd/mm^2 (last night)
Synios DMLQ: ~400lm, ~310cd/mm^2
CFT90: ~5000lm, ~200cd/mm^2 (30A)
Great work :+1:
I bow before you fine sir, absolutely amazing project and outstanding execution.
Amazing work !
I can’t wait for the final measurement after the focus tuning :sunglasses:
Is there any spill ? Or does the recoil configuration make a pencil beam only ?
Thanks guys
Yes it is beam only, like an aspheric thrower.
No chromatic aberration though, so spot is all evenly coloured.
Also the spot is a round shape due to the large difference in angles that the reflector picks up light at, no square die projection.
Those flashlightlens lenses are that clear I’ve had people putting fingerprints all over them as they dont believe it has a lens on it at all. :person_facepalming:
I’ve only just caught up with this build. Seriously impressive!!
You are joining in in the fun on the next scratch-built comp, no??
With the pump getting hot, I’m wondering if you could run it at a lower voltage?
Great build! 
Drool!
How about a motorized tripod and a remote control for it?
Awesome!
So how does the beam profile compare to a typical reflector light?
I don’t really know what to say… Very bright night(so it naturally downgrades cd performance) and just incredible brightness at that distance.
But maybe you’ll really have to stay with black flat. Why?
Djozz also made small aspheric Synios build and while he expected candela boom it even did not managed to out throw good old XP-G2:
Hahaha true
A lower voltage would reduce the heat, but also the flow rate.
Now that I added a heat path to the body it isn’t heating up
I might join the scratch build contest, however it took a year to plan and design this light, and there are still small things going wrong, so I doubt I would do a project this complex for a scratch build contest.
I bought a tiny tripod for it, so I can point it at different angles easily:
Well the biggest difference is it has no spill, also the corona is much less pronounced, so the transition from spot to darkness is a lot faster as you can see in the pic.
The spot is not perfectly round though, not sure if it is my focusing or just the reflector’s precision.
I will need to do further tests with the synios LEDs.
My first test from two days ago didn’t look like higher intensity than the OptoFire but it was definitely not well focused.
First I want to measure the black flat though.
That is really awesome work. I love to see envelopes being pushed.
Wooooaaaah! I missed this thread for weeks and was drawn in again by the mention of beamshots. This is fantastic work Enderman! A much cleaner build than the Optofire, and a bigger/further/better beam of course! Very very nice, I’m looking forward to more beamshots and numbers.
Great Job man! really awesome… group buy?
Thank you, that’s what I love to do
A lot more complicated too!
Same, I’m curious to see how far off my estimates are.
Haha thanks, very few people are interested in spending that much money on a thrower 
Who knows, maybe in the future I can design a more affordable one that people would be willing to buy.
I mean, silent thunder ordnance sells mediocre 3D printed flashlights for hundreds of dollars when their parts only cost less than a hundred.