On the design of the board, you Can use 0603 pads for space, and still be able to use 0805 components, it is a “high density ” pad footprint, but you already knew that 
Awesome thread, let’s get this sukka started 
Both mattaus and wight had good designs but haven’t heard much about them late
To save board safe would the Atmel ATtiny10 be sufficient, I found a PCB based ZIF socket, might work for programming, just need a good code writer to whip up an awesome UI ; )
For a power cycle only, more simple UI yes it’s probably enough, plus with the attiny10 a 10f322 is a direct swap, same pinout between AVR & PIC. One thing tho is no voltage divider input so no voltage monitoring on the attiny10
With the initial design being for a dual switch light (courui is side switch only but I’ll be installing a tail clicky) it’ll have to be something bigger to run momentary FW.
Ok looking at the Vishay SL42 datasheet (covers the SL43 also) I see that the IF (AV) rating is different from Al to FR4 and that on FR4 its only 4A, is this still safe to use at 8A output on an oshpark board (albeit with a large Cu pour) considering that?
I didn’t notice that, good catch. Probably best to find a different one
Allright here's my parts list, look good?
1 MAX12820
2, 3, 9 1uf 16v 0805 (I have a reel of these)
4 Vishay Dale 2515 .025ohm 2W 1%
6 Diodes inc Schottky 10A 40V PowerDI™ 5 (I choose this slightly more expensive and higher rated diode for a few reasons, one being this package is smaller than the more common DPAK and also because while its more expensive individually it offers a better bulk discount)
7 AOD510 (exceeds all requirements, has great low RDS(on) and I have a hundred of them)
8 For my use a 12F617 but probably make an ATTiny13A version at the same time for everyone else
10 470ohm 0603's cause again thats what I already have on hand
hopefully links work, digikey is strange...
Tiny10’s can have issues being programmed in C. Like very easy to run out of RAM and stack space.
Yeah, just outside Raleigh; I’d love to
Looks good to me. The links didn’t work, so just be sure the Maxim part is correct since it looks like there’s a typo in the part number
Awesome man… So after this is out we should have a go to buck and direct drive in the blfdd?
Allright guys, after a little bit of a headache here’s the .sch. Now I need to find the dimensions of a Courui driver, anyone got one to measure?
Double check the direction that diode is facing
5-8 amps with constant current? If this driver turns out well, then ill just say...
Good catch, fixed. And while I’m waiting for either one of my Courui’s to get here or for someone to hook me up with measurements, just for S&G’s I thought I’d see if it’d fit in 26mm, definitely not even close!
Try using a smaller footprint FET like the LFPAK56, about half the size and very low Rds-on.
Very first draft of the very first board, AVR based for you guys (cause if it was for me I’d make everything in PIC). Wish I cold be working on the Courui driver but no one’s yet came threw with measurements or a driver I can borrow…
Notice there is only one remaining air wire (which I cant find, even when I turn off all layers) and it almost passes DRC (only has a couple of clearance errors)!
NICE)!! smash compments, fix silk scrern,but daggum most AWESOME what size driver and what will it go in when you are done?
42mm for TK61. I have some more components to add to the other side including a smart latching FET based switch to kill the buck chip (since it doesn’t have a low power standby mode), that’s what the 2nd e-switch will do, one for power and one as the normal AVR momentary FW input. That will all require major changes, I just needed something to show for what I’ve got in this already so I threw this together.
Sorry C_K, I loaned my Courui to a mate for the night. I should be getting it back tomorrow, so I can give you dimensions in about 24hrs from now if need be.
…So he ‘forgot’ to bring it back in to work today….
If you need other measurements, like shelf width, etc., let me know.
Yes I need everything, I also need the spacing of the cells so I can get that figured out.
Question, will it be possible to drill and tap mounting / ground holes (2 or 3) in the ledge the driver sits on to be able to screw it down? With the series conversion driver orientation will be critical.
This is what I’m working on in the mean time, there are several components missing for a smart latching switch (that will run off a coin cell) that uses a FET to kill power to the MAXUM chip, this will allow both buttons on the TK61 to work as normal, one as power (turn the FET on/off) and the other as the one mode change switch everyone uses for the different AVR momentary FW’s. The ATTiny13A wont control the FET at all, the Li coin cell will power a small iC to handle that part.
As you can see this is version 0.1, there are several issues I see right off the bat so still very far from having anything to order.