YuvalS's Hand Made Class, 7th Annual BLF/OL contest entry topic

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YuvalS
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YuvalS's Hand Made Class, 7th Annual BLF/OL contest entry topic

So I am planning on building a headlamp, hopefully I will finish it by February.

The body will be made of aluminum to double as heat-sink and the battery box will be made of some kind of plastic. both will be build using hand tools.

I want to print my own driver but I have no experience with printing circuits so maybe I will use a commercial driver and modify it.

As a FW I am planing to use my own code that is need some improvements.

Welcome to share your thoughts.
Yuval 

EDIT: 29/02/2020
Just before the deadline, I wanted to thanks all BLF members that helped and encouraged me during the build and especially to the annual BLF/OL contest team that pushed me to build the light Smile
I made a short video to summarize the process so people don't have to read the entire thread:
 

And here is pictures of the final result:
 

Evanualy, I did used some modified commercial driver and didn't print my own, maybe for the next year competition....

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My BLF/OL contest entries: 7th 8th 9th 

Edited by: YuvalS on 02/29/2020 - 08:30
sb56637
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Sweet! Really looking forward to it.

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CRX
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Sounds good, always nice to see a self built headlamp Thumbs Up

MRsDNF
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All the best for the build YuvalS. Thumbs Up

 

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.

 

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MRsDNF wrote:
All the best for the build YuvalS. :THUMBS-UP:


Thanks MRsDN, you too.

So today I made the preliminary sketch of the body. 
I am planing to built it using 3 pieces of 6mm Aluminum glued together.
6mm Aluminum is easier to buy and easier to work with using the tools I have.
3*6mm = 18mm will give me enough space for a 17mm driver and 14mm optics + 2 mm mpcp (=16 mm) 

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My BLF/OL contest entries: 7th 8th 9th 

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Nice start Thumbs Up

  

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subscribed! Thumbs Up

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So my GF travel to Germany for the weekend and I had an opportunity to take over the living room and convert it into a workshop cool


I started to build the body. Since it it made out of 3 pieces of aluminum I decide to first attach the 3 pieces together using screws. It will enable me to precisely drill the 2 mm drills for the screws around body.
I did not manage to use the drill press before the pieces are screwed together so I had to drill another set of drills by hand foot-in-mouth

I tapped M4 to the bottom aluminum piece


And now I screwed all pieces together and can continue working on body but I have to wait for the next time I will be able to conquer the living room wink

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My BLF/OL contest entries: 7th 8th 9th 

grin
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Good stuff. You may find it easier to tap the holes with a battery drill, it is easier to keep the tap straight. Use WD40 or something similar to lubricate it.

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grin wrote:
Good stuff. You may find it easier to tap the holes with a battery drill, it is easier to keep the tap straight. Use WD40 or something similar to lubricate it.

 

I have lubricant in this green plastic. I also use it for drullind and sawing but never thought of using a WD40, maight be easier to apply, THX

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You are in so much trouble when your GF reads this thread YuvalS. Love your style. Thumbs Up

 

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.

 

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YuvalS Nice build. subscribed Beer

Note: If you do not want oil on your projects, dish soap works just fine.

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Good start Thumbs Up

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Nice room conversion LOL Good to see you make a start Thumbs Up

  

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After the progress yesterday I wanted to continue working on the body after work. Unfortunately my neighbors are not big fans of me building lights at night (TBH they are also not like it when I build other stuff) cry

luckily, I have found a 220v outlet next to the road around my neighborhood, far from any building and was able to work there 


As you can see I have took CNCman advice about using dish soap as a lubricant since it is easier to use when working outdoors


It was quit challenging to drill 12 2mm holes in a 5mm border but I am quite happy with the result, no drill pierced the side of the body and I only broken one drill bit sealed

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My BLF/OL contest entries: 7th 8th 9th 

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YuvalS wrote:

luckily, I have found a 220v outlet next to the road around my neighborhood, far from any building and was able to work there 

 

Perfect combo of will and "do with what you have" spirit ! 

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YuvalS wrote:
After the progress yesterday I wanted to continue working on the body after work. Unfortunately my neighbors are not big fans of me building lights at night (TBH they are also not like it when I build other stuff) Crying

luckily, I have found a 220v outlet next to the road around my neighborhood, far from any building and was able to work there

That’s dedication. Thumbs Up

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What they said ^ Thumbs Up

  

YuvalS
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Today I sawed the corners and turned the rectangle octagonal.
Unfortunately I forgot the jigsaw blade at home and the Dremel blade is too small, so I had to use a hand saw.


After sawing, I smoothed it all out using a file. The result is not perfect, but since it all done using only manual tools I am quite satisfied.

 

The body is finally take shape

 

 

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My BLF/OL contest entries: 7th 8th 9th 

CRX
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You’re crazy mate Big Smile Thumbs Up
Couldn’t tell where you were this time Smile

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Looks like good work under less than ideal conditions. Thumbs Up

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Love the new workshop. 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.

 

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Thanks guys, it is the same workshop as previous pictures .
Looks like I will not change this place unless someone will kik me from there.
I am also using this spot to work on my camper car conversion so it is a busy workshop money-mouth 

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My BLF/OL contest entries: 7th 8th 9th 

YuvalS
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Back to the "Workshop" today for drilling the body using 27mm Holesaw to create some space for the optics and electronics

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My BLF/OL contest entries: 7th 8th 9th 

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Looks nice so far. Smile

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I cannot see several pics in post #26.

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Looking good,
I once built a Datsun 180b engine in a kitchen in a flat in Melbourne.

sorry all images down
thanks photobucket

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raccoon city wrote:

I cannot see several pics in post #26.

Same problem here

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lostheplot wrote:
Looking good,
I once built a Datsun 180b engine in a kitchen in a flat in Melbourne.

Can I tell everyone what else you have done mechanically in houses?

 

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.

 

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