FS : LED centering rings / positioning / insulating – made to your specs (CLOSED)

Ahh yes. Thanks O-L, will fix that.

Also, I’ve measured the MT-G2 at .352” square. .365” seems like a lot of clearance. Should it be smaller?

Might just be my incorrect measurements. I got .362" and went with .365", but I can go check again.

Edit: I measured one that was on a star and got .360" one side and .357" the other side. I went and measured one by itself and I got .353" one side and .350" the other side, so the difference has to be solder or flux or expansion from heating and soldering, (possible? probably not).

I would at least go with .360" myself, but you're the machinist and I am not the most knowledgeable on clearances and dimensions. My digital caliper is cheap, and not 100% reliable, but then again, neither am I.

Oh, the three I "gave specs for", are just suggestions, cause I haven't seen any other specs come out. I can't say they are the best or the right ones, just ideas that might work.

For sure, I appreciate it. I modeled the squares at .360”. I might have to add little notches to all of the LED squares to allow for the excess solder blobs… Or the end user could use a straight razor to cut off the excess solder. That works well in my experience.

Very cool to offer these things, exactly what I need right now. :slight_smile:

I’ll work out the dimensions and get back to you!

Any chance you could do black nylon instead of white?

Would everyone prefer black? It would be easiest to offer one color because I will cut these at the same time from a single sheet. I can do black though. Things made from thin sheeting like O-L’s .015” washers may not have a color choice, but I will look into it.

Hoop.
I don’t want to go off subject, but it looks like you have the know how and means to make a 21mm SinkPad centering tool so we can make our own 16mm XHP70 and 16mm XML Color SinkPads. Stick the 21mm SinkPad in the plastic centering tool and punch it out with a 5/8” (16mm) punch. Kinda like you see in this video. Is something like this doable? If yes then all we got to do is buy a centering tool from you and pay a visit to Harbor Freight.

My hunch is that simply punching the stars may not create a sharp enough edge to prevent shorts, but it may be ok with a little bit of cleanup. I think you could punch them close to 16mm but oversize, then use a sander to finish the job. This would save time over only using the sander. The sander method has been successful.

I have however been re-machining XHP-70 boards from 20mm to 16mm, and they do not short. The star gets chamfered on both sides. I can also do this with the LED’s pre-soldered on the star without damaging the LED. These and the colored stars will be available shortly. I really had expected the star manufacturers to offer these by now but since they aren’t, it’s about to time to fill the void.

In regards to relief for the excess solder, I could do it a couple ways. The version pictured on the left is easiest, and I can complete those in a single operation. The partial relief on the right would require a fixture to be built for the secondary operation. For one off’s I’d have to stick with the left side version, but if a particular star becomes more of a standard offering, I could do the other style. Thoughts?

No preference for me regarding the cutouts for solder balls, so whatever is quickest/easiest. Personally I’ll just cut a bevel or cutout if needed with an xacto blade.

So my request would be for the following:


XHP70 led to fit an SSC-P7 C8 reflector. (either white or black is fine for these)

Quantity: x6
Led Cutout: 7mmx7mm (whatever is your standard for XHP70s)
OD: 12.5mm
Reflector Hole Diameter: 9.25mm
Thickness: 2mm base + ~1mm lip

Notes: Non-continuous lip as shown in your examples. No cutouts for solder balls required, no fancy outer shape, circular is fine.


SBT-70 led to fit KD 86mm reflector (would love it if these could be black if possible)

Quantity: x2
Led Cutout: 11mm x 10mm (rectangular but centered)
OD: 26mm
Reflector Hole Diameter: 19.5mm
Thickness: 1mm base + ~2mm lip

Notes: Continuous circular lip. No cutouts for solder balls required, no fancy outer shape, circular is fine.


XML2 led to fit KD 86mm reflector (again black if possible)

Quantity: x2
Led Cutout: 5mmx5mm (XM-L2 standard)
OD: 26mm
Reflector Hole Diameter: 19.5mm
Thickness: 1mm base + ~2mm lip

Notes: Continuous circular lip. No cutouts for solder balls required, no fancy outer shape, circular is fine.


Hope that’s enough info, if you need clarification on anything let me know.
Cheers and thanks again for offering this, very cool!
Linus

EDIT: Changed lip to 2mm on 86mm rings

It seems like every time I have to use a butterfly spacer I have to cut more off because the solder pads are under the tabs. A design with the square cut at 45 to the tabs would fill a missing nitch. The 16 mm Sinkpads are my source of angst.

Linus, for your C8 gasket, some of the light will be blocked due to the height and the 120* LED emission angle. I think the best I could do to correct this is use 1/32” stainless steel dowel pins and also put a heavy chamfer on the square pocket. Let me know what you think:

I haven’t modeled the other ones yet.

I made the base extra thick to give me a bit of adjustment room regarding focusing of the led. i.e Gives me some leeway in terms of pulling the emitter out of the reflector some ways, I intend to sand them down to a minimum once I’m happy I’ve found a decent compromise between minimizing the donutyness of the hotspot and maximizing output on these particular reflectors. :slight_smile:
I wish I could give you some more exact dimensions to fully take advantage of your great service but this will have to do for now.

The dowels are a cool idea but I’m happy just to go with something standard like these

Cheers
Linus

Added LinusHofmann’s rings to OP.

Added XP / Nichia c-ring for new style SMO C8 to OP. Also for Convoy S2+.

I would like a Convoy S2+ xp/nichia c-ring;
xhp-70 C8 ring;
and a 16mm xhp-70 board if/when you decide to do these.
Thanks for doing this.

Awesome thanks!

Test cut a couple of the S2+ xp series rings. It seems the process is more forgiving than I thought it would be so I will probably be able to make these out of black acetal (delrin) rather than nylon. :bigsmile: Acetal machines a lot nicer than nylon and should require less deburring effort. I will test the process with acetal shortly.

Very nice looking! For me, I don't give a hoot about color, so anything will be ok for me.

Nice work hoop.

I would like to have one of the XML to KD 86mm reflector please.