What is the size of the reflector, díameter and depth, you might be able to find one designed for LEDs in that size
eh… I really don’t think that’s how it works. Allow me to refer you to all Maglite incan->LED conversions. Note that they all use a podium. Also note that the “Rebel reflector” from LED mags does not require this, that’s because it’s focal point is at the bottom rather than a few MM up. You need the LED to be where the filament was in order for the reflector to focus. HID just has a plasma gap or whatever, but the principle is definitely the same. Since the gap is smaller with HID, I expect the focus to be better.
I’m not saying you shouldn’t do the mod, I’m just trying to help you avoid making something that won’t work right. Planning on a podium from the start is really different from trying to add one after you can’t get the thing to focus. Testing will help you see what we mean though!
Mummify it with some sturdy tape to preserve the ano and get to hackin' .
And once you get the body tube free of all obstruction , feel free to let out a MUAH HA HA HAAAAAA .
Once you find the focal point you can chop off the base of the reflector, the part that's not needed anymore, instead of using a pillar. I suspect it will be pretty bad with a LED though even when it's in the 'best' location.
I think I’ll just scrap it. A reflector that won’t work and a hollow tube without a pill isn’t worth the work involved.
So make a 'pill'.
This was done with a hacksaw, file, drill press, & sandpaper:
2" dia 6061 barstock: http://www.ebay.com/itm/360856642037
I’m not so sure that the reflector won’t work (I’m not so sure that it will either). HIDs are not point light sources, but they are pretty small, like an LED. I would think that the beam would be much better than a lot of incan to LED conversions. (Am I wrong about that?) Plus, the reflector looks like MOP, how bad can the beam be? And comfy is totally right about chopping off the base of the reflector, that’s a great alternative to a pillar. The heatsink assembly still has to get high enough to put the LED into focus, but at least you don’t have to worry about how to thermally couple a pillar to a heatsink/pill combo without a lathe.
This looks like a fun host and I was really tempted to buy the thing myself! Plus, isn’t this size your jacket-pocket sweet spot?
I want to see how you solve MT clearance. Heck, comfy just made you a pill!
GL
When you chop off the unneeded part at the base of the reflector the hole automagically gets bigger. Solves several problems at once.
I decided to have a go at the innards. Things do not bode well. I twisted away with pliers from the top, yanking out a few springs and wires. I finally drilled a hole through and through.
It's solid all the way through. I don't think I'll be able to clear it. I even took a thick heavy steel rod and tried sledging it from both ends...it didn't even phase it.
It seemed like a good idea when I purchased it, but I didn't know I was going to run into this immovable plug.
After drilling a hole clear through the thing, does the material at the top (around the bulb socket. Looks like it has machining marks.) seem to be the same material as the stuff that was poured in from the bottom?
No, it’s some type of plastic/nylon. I’m assuming the stuff that was poured in is some kind of epoxy.
What about doing something like the cheapy smd led bulb replacements all over eBay, only with Cree led's? I'm picturing a copper/aluminum rod sticking up into the reflector with a few stars mounted around the original focal point. Probably unfeasible, but it would be different.
I have a plan, but nothing is going to happen if I can’t clear that plug.
Has something changed recently with the laws of physics/chemistry, where heat no longer softens/melts plastic??
I’ll put that on my list comfy. Do you think I should torch the top end? As a last resort I’ll bring it into the maintenance shop at work.
Burn’em outta there! Just kidding. Heat sounds good, or freezing it. Or Freezing it and then applying heat to the outside maybe.
Or sitting it under the drillpress and pressing it out?
I would probably attack it with one of these: http://www.dremel.com/en-us/Accessories/Pages/ProductDetail.aspx?pid=9901
Cut two slots front-to-back so you can break it into two pieces.
I just hit the plastic/nylon part with a mini torch. It started bubbling and burning like a tire. I have it sitting on the cement, it’s still burning away all by itself. Like a tire fire. I’ll just let it burn and see what happens.
Things are starting to heat up now. 