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

I find images on google confusing to post in forumd. Working niw

How do I order one? :beer:

Looking good.

Old git huh!?
Imma break a record on you! Whippersnapper! :smiley:

Just came back from a caving trip in Romania and find the heat sing waiting in the mailbox so I had to cut and fix it to the light.


Copied the light dimensions:


Roughly saw it by hand:


Removed unneeded ribs to create place for nuts:


Attached to light and file the edges:


Body is now completed and I still did not get the electronics from Fasttech (shipped on Dec 2nd) maybe I start working on the rear battery case

The heat sink looks really cool. :person_facepalming:
Any pictures of the caving trip?

:+1:



Wait till 2000 Lm will be connect to it....
I will get some pictures soon but not sure it is the right forum

Looks like you’ve nearly finished the host. Great work :beer:

Today I made the helmet mount from a 1.5 mm aluminum:

After cutting it to proper dimensions, I had to curve it so it will sit properly on the helmet:


Luckily a 18650 cell came out very handy to draw the 2 half circles at the ends:


To fold it precisely, I made small cuts at two sides of the Aluminum:


Unfortunately, I forgot about the cable gland when designing this mount so I had to file it a bit in order to allow a better pitching range :(


Lots of members here have posted up there caving pictures. Personally I find them fascinating.

Your light is coming along nicely. What thread did your gland have? After a couple of small ones myself.



This gland is shitty chinese one with no standard thread.
If you need small one I recommend the mini Lapp Kabel, Ip68 with standard metric thread.
I have used the M8 one for previous project and it is perfect for 2*0.75^2 cable.
https://www.ebay.com/itm/LAPP-KABEL-52001880-CABLE-GLAND-MINI-M8/171859331326?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2057872.m2749.l2649

Thanks for the link YuvalS. I did not think to look on Flea Bay. :beer:

While waiting to get the electronics I ordered from Fasttech (I am getting a bit worried that I won't get it in time to finish the light till the end of the month ) I decided to build the battery case:

I first saw the body from a thick cutting board, making a tight space for a double 18650 battery holder:


Then drilled holes for the screws and cable and file the battery holder to make some space for the wires:


I cut the rear and front covers from 2 mm Perspex:


And had to sand it:


After a lot of sanding:


:+1: Sanding can be a drag; sometimes it seems to take forever. Looking good. I hope you get the parts needed soon.

:+1:

Continuing with the battery box, today I soldered and glued the cable

First I wanted to easily identify the right polarity for the batteries even while changing batteries in the cave using the spare light:


So I painted half of the battery holder in red to mark the positive side :)


Then I soldered the cable (2P1S):


And last thing for today, glue the cable and seal the hole:


I had to glue it instead of using a cable gland since the hole is very close to the edge in order to allow the wires to enter the case below the battery holder.
I used shoe goo because is is perfect for this purpose: bond good to plastics, elastic and waterproof
Now I have to wait for the glue to cure...

The holders are looking good. :+1:

Today was waterproofing day....

I cut rubber seals for the battery box:

And for th head unit:


And glued everything


So again I have to wait for it to cure....

The next step (unless I finally get the electronics package) Is my patent how to secure the screws so I don't lose them while changing batteries, not sure if I can explain it in pictures maybe I shoot a short video

Always nice to see your progress.

I see you have a long weight. :person_facepalming: