Convoy 4x18 Luminus 90.2 mod with 86mm reflector ( FINISHED )

How much do you get to pay for this level of quality—it’s priceless i’m sure.

Go getcha one of those $1 budget beater lights with a round emitter, you will love the beam compared to that one.
Budget Beater

Super intrested with qhat you come up withw

OK, it’s time to get started this week machining the head, reflector, and copper heat sinks. Here are some tear down pics prior to machining.
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Also did some inspecting of the problem with the led offset and was able to find the problem. The mcpcb’s are never flat on any flashlight that I have checked and this one is exceptionally warped from the stamping process. It was tilted badly because one screw was tightened and the second was less tight to prevent bending and de-soldering the led from the mcpcb. The correct way to fix this ( every mcpcb ) is to use fine sand paper on a flat surface and carefully sand flat the bottom of the mcpcb.
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Purchased this computer/phone disassembly kit from Walmart for $15.00.

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Another problem with the Convoy is the switch leds do not come on ever.

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The driver looks to be wired for the switch leds. I will look into this problem soon.

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I LOVE when you have new projects CNCman, looking forward to this one VERY MUCH, glad folks with talents like yours (and others) keep this forum fun and interesting on what is possible. Maybe my wife will Let me buy that 5-axis CNC machine, next year :)) but then I would need to learn how to use it haha

can't wait for your updates!

Oh oh, my guess, cncman is going to machine a "head extension", that threads into the bezel threads and opens up wider to accept the larger reflector?

am I close?

I couldn't imagine you will machine a whole new head, at that point you would be making a New flashlight lol.

I’m going to thread the reflector directly to the head, no adapter this time, no room for it.
Strangely enough it will fit, unless it unexpectedly cuts thru the reflector. LOL
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Next it needs some copper heat sinking because it gets too hot too quickly.
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After that it needs a new bezel to hold the lens in place.
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Here is the free 2D CAD i have used for years, easy to learn.
FREE 2D CAD
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Thanks for the nice comments :sunglasses:
It is fun to make things and share that with you guys :smiley:

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That is an excessive amount of thermal paste between the shelf and the MCPCB. Interesting that the MCPCB was that warped and the screws were only tightened to a certain point due to the LED.

I always sand the bottom of my boards with fine sandpaper on a small mirror to get them very flat. It seems for the most part they are flat, but there are usually spots on the edge or by the holes that show signs of being sanded first before the rest of the board.

Looking forward to your mod CNCman!

Finished the SS Bezel today. Next up the head prep for heat sink.
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WOW! it looks awesome! you are a true craftsman, sir!

I got some ideas i need fabricated :)

This is looking good! I’m excited to see how it turns out. I’ve wanted to put a 86mm key reflector in an L2 for a while. I don’t have your skills though!

Just finished mating the reflector to the head.
Heat sink is up next.
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Amazing work.

It has been a busy week with no time to finish the heat sink. So here are some CAD dwgs I drew up before starting to verify fit before machining anything. The head threads are 64mm x 1mm 60deg. This was a total guess before purchase if the Convoy would fit directly to the 86mm reflector. Drawing dimensions were accurately drawn.
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The green in the middle is the MCPCB and LED.

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Amazing mod....LODI....Hope it can also fit to Convoy L7

Finished the heat sink. It was a tight fit after hand polishing it to go in with a running slip fit @ .0015 or .0381 mm clearance on both diameters for best contact with a little Arctic MX4 thermal compound added.
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This part was challenging to design and make. Calculating position and size on the 2D CAD made this possible. I highly recommend anyone wanting to learn CAD to get the 2D FREE version. HERE .
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I will do some measurements today for lumens and throw.
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Compaired to the MT07 Buffalo with the same reflector.



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Beam shots not great but very bright downstream.
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You are great !!! It is beautiful and certainly very performing, congratulations on your work, it's been a while since here on BLF I haven't seen such a well done customization. Truly a really beautiful job.

You should sell this modification in a kit ... I would be the first to buy it, it is so well done that it looks like a production production and not a customization.

WOW! just checking the thread again and you're done! AWESOME work cncman! It looks really good too, which i know you must have considered, but sometimes its all about the performance, i agree with Fedtro that this looks like it could be a production run!

I know for one, i would definitely buy this "kit" if it were ever made. only thing is it would cost more than the original light with the cost of just the machining hours and design. either way, nice work, so glad to be able to see it happen!

Congratulations, CNCman. This is amazing skill and imaginative.

I especially like the large SS bezel. You could sell this design to Convoy! I believe many of us BLFers would love to buy one if Convoy makes this from your design for sale. :+1:

Thank You, Fedtro and ArtieT59 and TermsakC for the kind comments :blush: .
It is fun mixing things up, to help everyone think outside the box and enjoy this hobby.
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In 5 yrs hoping to retire and get a small CNC Router, maybe scratch build it to get the rigidity needed to thread mill and a 4th axis to do designs on battery tubes. At that time the door will open to do more things for everyone, and I am looking forward to doing this and not for profit. Right now, time on the machine and availability is very limited. :wink:
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As for selling design to convoy, I never thought anyone wanted it, they are welcome to copy it, but for a production run it will work without the heat sink and the reflector uses a light thread locker for security.
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