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

43 posts / 0 new
Last post

Pages

CNCman
CNCman's picture
Offline
Last seen: 4 hours 44 min ago
Joined: 04/07/2018 - 10:10
Posts: 1204
Location: Mississippi Gulf Coast
Convoy 4x18 Luminus 90.2 mod with 86mm reflector ( FINISHED )

**Hi all Big Smile
I was planning a scratch build for a 86mm reflector and Luminus 90.2 but was unsuccessful finding a driver.
Thinking maybe a flashlight can be modded to accommodate my plan, the search led me to this Convoy 4×18.
Now it was a guess if it would work and after receiving everything, measuring, drawing it on Cad, it will fit, surprisingly. Cool
This will take some time, so posting pics as it progresses, just for fun.
.

.

.
It is hard to see but the led is tilted and off center causing a terrible beam.

.
I cannot get a good pic but you can slightly see it here. There is no round hot spot and further away is worse.

.

.

.

.

.

.

.

.

.
Here is the 86mm reflector for comparison.

.

Edited by: CNCman on 08/28/2021 - 09:24
CNCman
CNCman's picture
Offline
Last seen: 4 hours 44 min ago
Joined: 04/07/2018 - 10:10
Posts: 1204
Location: Mississippi Gulf Coast

New reflector with bezel.

.

.
Head modded for heat sink.


.
Reflector modded finished.



.
Heat sink.





.

.

.

.

.

.

.

.

.
Here are the before and after numbers. Big Smile
Note: lumen tube numbers are elevated slightly from inaccuracy of my lumen tube.
.
Stock:
Lumens: 4800
Throw: 1004 meter
CD: 252392
.
Modded:
Lumens: 5400
Throw: 1742 meter
CD: 758680
.
The end result was very good. It runs much cooler and longer. The beam downstream was no comparison.
No mod to driver or batteries, the only difference was the reflector and heat sink.
.
A deeper reflector does make a difference in throw. It throws better than the Buffalo with the same reflector at 1192 meter using a Lexel driver at 12v 6a and a XHP 70.2 with 9000 lumens. Proof as stated at Aliexpress that it was made for a SBT 90 led.
.

.

.
.
Here are the dims for the reflector if someone wants to do this mod. It is not too hard to do on a manual lathe like I did.
The threads in metric are 64mm x 1.0mm or 2.519 × 25.4 tpi ( I used 26 tpi on my lathe ).
Turn the diameter to 64mm ( 2.519 ) and 37.4mm ( 1.472 ) from the small end of the reflector.
.
You can buy the reflector HERE
.
You can get the 86.3mm lens HERE
.

.

.
Here are the dims for the bezel, no threads.
PM me for help with the bezel, mounting it was tricky, but not complicated. Wink
.

.

zoulas
zoulas's picture
Offline
Last seen: 4 hours 22 min ago
Joined: 06/01/2020 - 08:35
Posts: 1945

How can you fit a bigger reflector in the same host? The one you have pictured looks way too big.

raccoon city
raccoon city's picture
Online
Last seen: 9 min 38 sec ago
Joined: 10/06/2010 - 02:35
Posts: 17084
Location: रॅकून सिटी Palm Desert CA USA

Good question.  :-)

TMaxxJJ
Offline
Last seen: 4 hours 28 min ago
Joined: 02/01/2018 - 03:18
Posts: 409
Location: England

zoulas wrote:
How can you fit a bigger reflector in the same host? The one you have pictured looks way too big.

Clue’s in the OP’s name. Sit back and watch Wink
raccoon city
raccoon city's picture
Online
Last seen: 9 min 38 sec ago
Joined: 10/06/2010 - 02:35
Posts: 17084
Location: रॅकून सिटी Palm Desert CA USA

TMaxxJJ wrote:
zoulas wrote:

How can you fit a bigger reflector in the same host? The one you have pictured looks way too big.

Clue’s in the OP’s name. Sit back and watch Wink

Oh...

Duh!  :THUMBS-UP:

zoulas
zoulas's picture
Offline
Last seen: 4 hours 22 min ago
Joined: 06/01/2020 - 08:35
Posts: 1945

Well, he is gonna have to “CNC” the host. This should be interesting.

CNCman
CNCman's picture
Offline
Last seen: 4 hours 44 min ago
Joined: 04/07/2018 - 10:10
Posts: 1204
Location: Mississippi Gulf Coast

zoulas wrote:
Well, he is gonna have to “CNC” the host. This should be interesting.

.
Yep, everything is going on the operating table. We need more entertainment here at BLF, thought this would be fun to see.
It is going to fit, and look good. I hope. Cool
.

.
kennybobby
kennybobby's picture
Offline
Last seen: 1 hour 2 min ago
Joined: 05/10/2017 - 09:13
Posts: 940
Location: huntspatch, alabama

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

Quote:
It is hard to see but the led is tilted and off center causing a terrible beam. . I cannot get a good pic but you can slightly see it here. There is no round hot spot and further away is worse.

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

Now i used to think that i was cool,
drivin' around on fossil fuel,
until i saw what i was doin',
was drivin' down the road to ruin. --JT

Redlyne22
Redlyne22's picture
Offline
Last seen: 1 week 2 days ago
Joined: 12/25/2017 - 07:02
Posts: 221
Location: United States

Super intrested with qhat you come up withw

Sometimes being a newb is the best part of a hobbie

CNCman
CNCman's picture
Offline
Last seen: 4 hours 44 min ago
Joined: 04/07/2018 - 10:10
Posts: 1204
Location: Mississippi Gulf Coast

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.
.
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.
.
Purchased this computer/phone disassembly kit from Walmart for $15.00.

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

.

.

.

.

.

.

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

.

.

.

.

ArtieT59
ArtieT59's picture
Offline
Last seen: 1 hour 12 min ago
Joined: 02/25/2020 - 17:55
Posts: 2984
Location: CT, USA

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 LOL but then I would need to learn how to use it haha

 

can't wait for your updates!

[FLF] Five Light Friday https://budgetlightforum.com/node/78749

Check out some of my new lights (picture heavy) and quick first impressions of them here: https://budgetlightforum.com/node/77180

My Sft40 beamshots / comparison thread: https://budgetlightforum.com/node/78100

ArtieT59
ArtieT59's picture
Offline
Last seen: 1 hour 12 min ago
Joined: 02/25/2020 - 17:55
Posts: 2984
Location: CT, USA

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.

[FLF] Five Light Friday https://budgetlightforum.com/node/78749

Check out some of my new lights (picture heavy) and quick first impressions of them here: https://budgetlightforum.com/node/77180

My Sft40 beamshots / comparison thread: https://budgetlightforum.com/node/78100

CNCman
CNCman's picture
Offline
Last seen: 4 hours 44 min ago
Joined: 04/07/2018 - 10:10
Posts: 1204
Location: Mississippi Gulf Coast

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
.
Next it needs some copper heat sinking because it gets too hot too quickly.
.
After that it needs a new bezel to hold the lens in place.
.
Here is the free 2D CAD i have used for years, easy to learn.
FREE 2D CAD
.
Thanks for the nice comments Cool
It is fun to make things and share that with you guys Big Smile

.

NeutralFan
NeutralFan's picture
Offline
Last seen: 3 hours 35 min ago
Joined: 03/20/2014 - 19:22
Posts: 1542
Location: Wisconsin, USA

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!

I’d rather use my flashlight around the house than turn on the lights.

CNCman
CNCman's picture
Offline
Last seen: 4 hours 44 min ago
Joined: 04/07/2018 - 10:10
Posts: 1204
Location: Mississippi Gulf Coast

Finished the SS Bezel today. Next up the head prep for heat sink.
.

.

.

.

.

ArtieT59
ArtieT59's picture
Offline
Last seen: 1 hour 12 min ago
Joined: 02/25/2020 - 17:55
Posts: 2984
Location: CT, USA

WOW! it looks awesome! you are a true craftsman, sir!

 

I got some ideas i need fabricated Smile

[FLF] Five Light Friday https://budgetlightforum.com/node/78749

Check out some of my new lights (picture heavy) and quick first impressions of them here: https://budgetlightforum.com/node/77180

My Sft40 beamshots / comparison thread: https://budgetlightforum.com/node/78100

Superstocker
Superstocker's picture
Offline
Last seen: 2 hours 26 min ago
Joined: 11/28/2018 - 21:22
Posts: 305
Location: United States, Virginia

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!

CNCman
CNCman's picture
Offline
Last seen: 4 hours 44 min ago
Joined: 04/07/2018 - 10:10
Posts: 1204
Location: Mississippi Gulf Coast

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

.

.

.

.

.

.

.

.

.

sleasys14
Offline
Last seen: 1 day 17 hours ago
Joined: 05/11/2018 - 16:23
Posts: 66
Location: charleston wv

Amazing work.

CNCman
CNCman's picture
Offline
Last seen: 4 hours 44 min ago
Joined: 04/07/2018 - 10:10
Posts: 1204
Location: Mississippi Gulf Coast

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.
.
.

.
.

.
.
The green in the middle is the MCPCB and LED.

.
.

Chinaheart
Chinaheart's picture
Offline
Last seen: 3 days 12 hours ago
Joined: 07/19/2019 - 22:56
Posts: 274
Location: Philippines

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

 

CNCman
CNCman's picture
Offline
Last seen: 4 hours 44 min ago
Joined: 04/07/2018 - 10:10
Posts: 1204
Location: Mississippi Gulf Coast

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.
.
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 .
.
I will do some measurements today for lumens and throw.
.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.
Compaired to the MT07 Buffalo with the same reflector.



.
Beam shots not great but very bright downstream.
.

.

.

.

.

Fedtro
Offline
Last seen: 9 hours 1 min ago
Joined: 07/17/2020 - 10:40
Posts: 129
Location: Corropoli, Teramo, ITALIA

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.

 

Fedtro
Offline
Last seen: 9 hours 1 min ago
Joined: 07/17/2020 - 10:40
Posts: 129
Location: Corropoli, Teramo, ITALIA

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.

 

ArtieT59
ArtieT59's picture
Offline
Last seen: 1 hour 12 min ago
Joined: 02/25/2020 - 17:55
Posts: 2984
Location: CT, USA

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!

[FLF] Five Light Friday https://budgetlightforum.com/node/78749

Check out some of my new lights (picture heavy) and quick first impressions of them here: https://budgetlightforum.com/node/77180

My Sft40 beamshots / comparison thread: https://budgetlightforum.com/node/78100

TermsakC
TermsakC's picture
Offline
Last seen: 41 min 30 sec ago
Joined: 06/05/2021 - 22:47
Posts: 262
Location: Singapore

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. Thumbs Up

CNCman
CNCman's picture
Offline
Last seen: 4 hours 44 min ago
Joined: 04/07/2018 - 10:10
Posts: 1204
Location: Mississippi Gulf Coast

Thank You, Fedtro and ArtieT59 and TermsakC for the kind comments Blushing .
It is fun mixing things up, to help everyone think outside the box and enjoy this hobby.
.
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
.
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.
.

will34
will34's picture
Offline
Last seen: 24 min 39 sec ago
Joined: 12/18/2012 - 00:12
Posts: 4091

Great mod! Fitment and finish looks like it came from the factory

dthrckt
dthrckt's picture
Offline
Last seen: 1 day 14 hours ago
Joined: 11/08/2011 - 10:11
Posts: 4614
Location: Upstate NY

Very impressive. Now, if someone would make a light just like this but twist zoomie, I could probably be all set for a long time lol

CNCman
CNCman's picture
Offline
Last seen: 4 hours 44 min ago
Joined: 04/07/2018 - 10:10
Posts: 1204
Location: Mississippi Gulf Coast

Thanks everyone Big Smile
.
.
Here are the before and after numbers. Big Smile
.
Stock:
Lumens: 4800
Throw: 1004 meter
CD: 252392
.
Modded:
Lumens: 5400
Throw: 1742 meter
CD: 758680
.
The end result was very good. It runs much cooler and longer. The beam downstream was no comparison.
No mod to driver or batteries, the only difference was the reflector and heat sink.
.
A deeper reflector does make a difference in throw. It throws better than the Buffalo with the same reflector at 1192 meter using a Lexel driver at 12v 6a and a XHP 70.2 with 9000 lumens. Proof as stated at Aliexpress that it was made for a SBT 90 led.
.

.

Pages