D.I.Y. Illuminated tailcap

Thanks PD68 for that useful tidbit!
I removed the bleeder resistor and it functions normally just like before, eliminating OTC damage as a cause.
Without the bleeder, the resistance of the driver is ~22k and works normally without the tailcap. With the lighted tailcap, the MCU must be remaining powered as the OTC never drains and thus the mode always switches no matter how long it has been off! More investigation is needed.

I suspect the solution is a higher resistance but not so high that the MCU remains powered.

Rev6 needs an mcu, and so far is mostly untested.

If you want just a ring on top, you will want one of the Rev5 boards (one is unlisted, I’ll fix that tonight. The BIG SWITCH version I just did for Matt should work well) and/or a Rev4 board if you want the added utility of the little switch on the bottom.

If you look in the OP, I have linked the post #’s of where each board version is introduced. There’s a bit more info in those posts

Cool.

The whole idea of these tailcaps is based on observation and not some high level of electrical experience. Most of what happens between the tailcap, OTC, and bleeder is still essentially unknown.

So keep us updated on what you find

Well said PDog… each build is a new adventure! They are fun to work at, great to look at, but can be a pain in the behind to troubleshoot. I have one working properly on a Shadow JM07, it is red and orange and shows up well under the truck seat!

I tried a 2.2k bleeder + no tailcap and that shortens the OTC timings even when cold.

Finally got all my parts in and built one yesterday. Couple observations:

  • For a Convoy S2+, the stack is a bit thick. The tailcap retaining ring gets maybe one full turn. I just ordered more boards in 0.8mm, should fix that issue.
  • I can’t get normal operation out of my MTN-17DDm “New”. This is a common theme with the A6/Bistro firmwares it looks like, because of OTC and driver voltage issues. I’m trying to run 300ohm total resistance across the bleeder and tailcap (red LEDs + need a lot of light to see through the small gap in the S2+ metal switch). Following some advice earlier in the thread of running a 5:1 ratio, I set the tailcap pot to 250 and added a 50 bleeder resistor. Good brightness, but nothing but forward presses worked. Additionally, turning off the light, waiting 5 seconds, and turning it back on did not start from the bottom, but continued on the next higher mode. Lowering tailcap resistance had same results. Raising the tailcap resistance resulted in all of my short presses became medium presses, cycling the driver backwards into the strobe modes no matter how fast I pressed (not clicked, just pressing).

Not really sure what to make of that. Doesn’t seem like anyone has conclusively figured out how to work the mcu and OTC with the lighted tailcap, at least not at lower resistances. I’ll fiddle with it some more.

Hi pilotdog, do you know offhand if this will fit the Convoy S2? The Rev5.1x did not fit. The hole was too small to fit over the switch.

I was unaware the 5.1x did not fit the small omten, it was designed to. Probably Oshpark didn’t cut exactly where I wanted. The “Big Ring” version you linked will definitely fit over the switch, it will probably be even too sloppy. It might be too big around the outside too, so check the diameter of the washer that comes stock.

Rev5.1 for 14mm is the one I use the most and it has no issues with the small omten.

Thanks for your reply pilotdog. The S2 does not use the small omten like the S2+. It uses the larger one in the link here.

Hmmm i was not aware. Do you have calipers to measure the width of the post the hole has to go around? That might be the one matt had when he asked for the larger version

I will borrow a pair and report back. BTW, thank you so much. I did the tailcaps for my S2+ lights and I love them!

Also, if it’s close to fitting, you might be able to just drill out the middle a little. The Rev5.1x doesn’t have any hidden traces in the middle I don’t think

Has anyone had a chance to try out one of the new clear gaskets Simon made for the S2+ yet? He was hoping for some feedback. I would think djozz may have received them by now but I’m not sure. I sent out a few handfuls and I’m still sitting on a pile of them that I need to send to Richard. :blush:

I have not received them yet, there are still (probably, but I can’t see them) 6 red leds shining against the (still) black gasket in my red S2+.

Crap, I can’t believe I haven’t tried those yet. End-of-the-year school stuff has had me very busy with all these kids. I’ll try and get that done this weekend and report back. Sorry :confused:

Well…. I was waiting for what other people think, but I ended up not using them. They obviously allow more light through than the black and I’m grateful Simon made the switch.

But, they still block more light than a nylon glove, and I couldn’t get the retaining ring to screw down because of the thickness

Same here, got maybe 3/4 of a turn. I ordered 0.8mm boards to solve that; got the switch boards today and waiting for the ring boards. They should fit better. Still can’t figure out a good bleeder/tailcap combination (with decent current) that doesn’t mess up the modes, though. Need ~10ma to get a nicely visible red light on an S2+.

Not much to report, they work as expected. I’m having issues with the switch stack being too thick and my driver modes not working correctly, but the clear gaskets aren’t part of those problems. As far as I can tell they are exactly the same as the black ones. They work fine but you need decent current to get it visible - 10ma with red LEDs looked good to me while testing (would be less with other colors). Would be nice if the gaskets were totally clear but the current ones are much better than the stock black gaskets and definitely usable.

This thread is pure win, thx Pilotdog68 and contributors, i realized i need an amber gold lighted tailcap on my beside table torch more than anything in the world.

I finally got the clear gaskets in the mailbox, and more than I ould ever expect: 140!

I put one in my red S2+ and can finally see the red tail light! :slight_smile: The light has the driver scavenged from my blf-x5 so the driver timing is prepared for the lighted tail. I used the same tail resistance as the blf-x5/6 to retain normal driver performance, but with 6 red leds. Nevertheless it draws only 0.78mA. So the leds are pretty dim and the metal tailcap does not help with that: works as a dim locator light for use at night, but nothing spectacular. I will swap the resistor to get to 5mA and a bit more light (and 10 days runtime on a fresh 18500 cell). For now: