Yea, these posts/discussions really help me figure out what to do and what works best etc.
I really would love to be able to thread the inside of a p60 host and get a nice chunky copper pill threaded to fit but I just don’t have the tools or the money to get someone to do it for me. I am sticking to truly budget as possible.
The direct bond is to get the heat away from the LED as quick as possible. The extra thermal mass is for it to be able to hold more heat. Adding copper in the p60 should also help heat move faster to the host as a lot of it is just air initially. I will also use copper foil to wrap these drop-ins to a tight fit too to get as good as possible heat transfer from the drop-in to the host. I’m currently have 2 debates about which way to go for each drop in.
For the nichia I am going to first try and just direct bond the LEDs directly to the copper chunk. If this becomes too hard to do I will make a separate star. If this is still too hard, I’ll just stick with using a typical aluminum star.
For the XML, I’ll try boring out the brass in the center and just sticking a whole copper rod in it. If that is too hard, I’ll go with a copper star route or get a 16mm sinkpad if those are out by then.
I most likely will be running these relatively “conservatively” at 3amps max each. This will probably net 700 lumens OTF for the XML2 and 500 lumens OTF for a triple nichia, hopefully.
Once these build are done, I’ll probably also build one of those custom IS so I can get some relatively accurate lumen measurements.