Earlier this afternoon I did a little more work on this project.
I silver soldered the two nested rings together and simultaneously soldered the pair to a piece of copper to cap one end. Why will become evident a little later.
Then it was filed and sanded round and the cap sanded to be smooth and flat.
That will have some holes drilled later. For now it will be set aside in the little box with other parts.
I verified the alignment and squareness of the soldered together copper heatsink and the other pieces.
The next stage involves making a wood block that will hold the 18650 cell in alignment with the driver, as well as provide a mount for the e-switch. The assembly with the heatsink and mcpcb, etc will be slipped inside a wood body.
Cutting with the table saw is difficult to photograph when one is both the sawyer and the photographer. Since I have managed to retain all my fingers and thumbs for 75 years I don’t want to lose one now. I took a picture of a slice being made with the saw static.
I look at this block to be a test block. I’ll probably have to do a second one after I figure out just how the idea in my head is going to be made real.
So far I cut the block to 19.95mm width. I cut slight notches and rounded one corner to fit inside the 90 degree angle formed by the heatsink and the 18 gauge copper strip.
The flaw in the block side is there because this piece of stck was a door at one time and there was a screw in there. No idea why, I don’t recall any reason for a screw there.Perhaps I used this piece for something else inbetween it being a door and me pulling it out of the scrap box today. The block is longer and taller than it needs to be. Also the flat copper strip is longer than it needs to be. It’s easier to cut off excess than to try and stretch something that is too short.
It is evident that the flat copper strip is 1mm narrower than the heatsink piece if one looks carefully. That will be hidden inside the light so is of no real concern.
There will now be a pause, an intermission, while I attend to some of life’s chores. .