Finished! Beamshots, Numbers!!!: 4x SBT90.2, active cooling, 12x 18650, custom copper heatsink

Wow!! amazing build… Thanks for sharing.

I love your ambition! Can't wait to see how this light turns out as you progress! Keep it up for sure!

Ohhh wow…bookmarked this share!

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Are you going to cut the reflectors to fit closer together ? Just checking what you are looking to build. :sunglasses:
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Yes exaclty, from these 73mm reflectors if you remove most of the “bezel” you end up with 67mm inner diameter. The inner head diameter is 128mm(4x 64mm possible), I dremeled out an extra 1.5mm from the inner diameter of the head and ended up with 131mm. I have to cut 2 sides from each reflector to get them to fit all together and also reduce their diameter to 65mm. In the end with tolerances mistakes etc I should end up with an inner diameter reflector set of 129-130mm. The original BLF GT94/GT4 (which I am trying to outperform) have an inner reflector diameter of 118-119mm so I am ok with it.

Reflectors are done. :sunglasses: Cut with a hacksaw in a jig from the hardware store and jb welded on a glass surface for flatness.







Almost 130mm, it is a really tight fit in the head, and 12mm wider than the BLF GT94 !

Part of the reflectors is covered by the bezel. I thought about thinning out the bezel to have more of the reflectors exposed. Measurmetns with and without the bezel showed only 1% improvement so maybe I will leave it as is.

And some numbers with the head not in one piece and not ready yet. Double 16awg silicon cable directly to the leds which are also connected with double 16awg in 4s.
I meassured 31.59A !!! with 4s3p :slight_smile: with the cables being extra long (extra resistance) until final assembly. Cells were at 4.16volts. WIth 1p I got 13amps and with 2p, 25amps. With the 3rd set of MJ1s I got the 31.5amps, so cells are not the limiting factor.

My lumen meassurment box is far from perfect but is the only method I have right now.
My Convoy C8 is meassured to have 852 lumens, and if we suppose it makes 1000lumens we have a factor of 1.17

The Astrolux MF02 meassured at 1743 and should produce 2000? Factor of 1.14

So lets suppose a multiplying factor of 1.15 for my box. The 4 sbt90s produced 21100 lumens which is pretty much spot on with the reviews of the GT94. Seems realistic to me.
If you spoted this suspicious c8 there, its not on. I just used to support the conical heatsink…

I need to measure kcd in the weekend, then de-window :wink: and meassure again.
A quick kcd meassurment showed 4.42 times more lux than the mf02 (4.42 times 400kcd=1.768Mcd) but only at 3 meters so not very accurate. I will need to test it more accurately and report back.
Last steps are to put in the fan and speed controller. If I dont break any bond wires by de-windowing it will be an amazing light.
Thanks for reading

Wow dude, color me impressed!!! :open_mouth: :partying_face:

Wow this is incredible! I can easily see you hitting 2 million lux if you are already getting 1.7 that close. Can’t wait to see more progress pics!

Quite the monster! I have mixed feelings about active cooling - I think it’s about the only route forward for sustained lumen increases, but waterproofing is out the window.

Man, I think I need to get a few more SBT90.2s. Not cheap, though…

Finally ready!

Fully assembled fully functional.










Side by side with the Astrolux MF02 (xhp35 hi).

The de-window gave me an 11% increase in candela and around 4% in lumens, measured 21890lm. I didnt notice any changes in the tint. Also I dont know if the reflectors need refocusing after delensing, I will leave it as is. However it gave the beam some artifacts (rings) which were not there before. Maybe later I will make some cut-outs to the bezel with a circular saw to have more of the reflectors exposed.
The potentiometer for the fan controller was placed on the left side to be easily operated with the left hand while holding the light. I made a wood knob for it. Looks a bit akward but I like it.
Total weight 2700gr or 5.95lb, not very practical but it was never meant to be.

I haven’t tested and wont test how long it lasts on turbo on max fan speed which is probably the number one question one would have. It does get warm after some minutes but the fan blows hot air and seems very efficient to me. At low fan speeds its pretty quiet but at max it really blows and whistles somewhat because of the many sharp edges at the intake. Doesnt bother me as I am never gonna use it for practical purposes. Just wanted it to be there as a feature.

Question: The driver is from the BLF GT4/GT94 and has a ceiling at 9.5-10amps and then double click to 31.5amp turbo. I want to disable the ceiling and have ramping up to turbo but didnt manage to find the right instructions manual. I dont know exaclty which firmware I am running. Does anyone have a clue? 4 clicks from on (which is supposed to be configuration mode if I am right) is locking the light out.

I will add later some outdoor beamshots when its dark enough.

Thanks for reading and for the kind comments

Very, very impressive !
And fun to read and informative :slight_smile:

Job well done!

Very nice build. I love the heatsink.
Pos tha to onomasis?

Wow!!! impressive… that copper heatsink design is awesome.

Nice Successful Finish Kourtinoksylo. :+1:
Very Big Torch !! Great Job building and designing this Monster ! :smiley:
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Not many of us are willing to take a new expensive light and tear it down, cut it up, modify it, and put it back together with handmade unique parts, bigger and better than before !! :sunglasses:
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You guys raise the ’ Mod Bar ’ and continue to carry Old Lumens Torch forward. :person_with_crown:
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Thanks, well I didnt think about naming it but a nice one would be Φώτης/Fotis lol

And the beamshots as promised. The tower is at exaclty 300m/985ft from my window according to google maps. A comparable light that I have in terms of throw is my MF02 so here they are side by side. Slightly different photo framing but you get the picture :zipper_mouth_face: Both are on turbo, just forgot to write it on the photo of the mf02




I used of course manual mode but automatic WB :person_facepalming: , tried my best without a tripod to get similar framing. Well this is what 11x more lumens and 4.5x more candelas look like compared side to side. Not only is the hotspot massively bigger and brighter but the flood is also very nice. The roof of the building in front of me is being lit while the MF02 gives you just a bright hotspot and minimum spill. Not even the trees below the tower are iluminated with the mf02.

Do you intend to measure the lux of the light?

Φώτης, very well suited!

Wow bro! I usually don’t like big fat lights but this is a MONSTER TUNE! :+1:

Amazing build. :slight_smile:

Now that I would pay $700 for, instead of static cooling big lights that makes no sense(I do own several big light including GT70 and MS18).