14500 hand warmer has a big 18650 brother, Mr Slick. Updated 18.4.15. Post 23.

Flashlight Modding and DIY Parts
1

My last flashlight I made now has a big brother. Its not quiet ready for action yet but all the machine work is done and all the parts to get it working have arrived. It just takes the guy with DNF (do not finish) to get it happening. I'm blaming a busy xmas schedule for holding things up but hopefully big brother will be emitting beams soon.

When these parts_____

_____ these other bits and pieces get put together big brother will be created.

The pill which will house a 16mm XM-L U2 and a KD 8x7135 V2 driver. This driver will run at 3 amps. I have left enough depth in the driver end of the pill that If I think I can add a couple of extra chips to it (which I have) without trashing the driver, it will still fit in the pill. All threads are 22mm x .75mm pitch to keep the light as small as practical.


I wanted to make this light a little different to try and get a sleek look so decided it would not have a tailcap as such. It is more a switch holder that screws into the end of the flashlight body. From a side on view you cannot see this holder. An o'ring sits in the bottom of the switch housing in a slight recess that seals on the taper on the outer edge of the switch holder. Drive screws allow the light to tailstand and add a bit of bling.


This picture better explains how it works. The battery cannot be inserted into this end. The switch is held captive by the switch holder and the step in the body. I have some colored o'rings on order which are not here yet. There was not enough metal left to put a deep enough groove to seal the head to the body for an o'ring so had to compromise with it sitting in a shallow groove at the end of the head.


The business end has a 20mm TIR 15 degree lens which is the first time I have used one of these lenses. If I'm not happy with it I have a 20mm reflector and lens ready to go. The lens sits on an o'ring in a slight recess in the lens and housing itself. You can just see it as a black shadow here.


And finally an assembled shot with the battery that will be used.

Diameter is 25mm and overall length is 122mm. Beam shots to follow, hopefully soon.


The plain finish looked a little sterile so asked the financier her opinion on what parts to sand blast. I don't mind the look and its a little different.


Left to right by usable lens size. 17mm OP reflector. 18mm 15 degree TIR. MF 3 mode P60 dropin.


Night shots. Approximate distance to shrub at the end of the driveway is 68 meters. All the lights are XM-L and running 3 amps.

MF 3 mode P60.


17mm OP reflector.


18mm 15 degree TIR.


MF 3 mode P60.



17mm OP reflector.


18mm 15 degree TIR.


To sum up I'm impressed with the TIR. One thing you dont notice is that it is shorter than any similar sized reflector I have keeping the overall length down while still keeping a nice beam pattern. As you can see the Beam spread is about half way between the smaller reflector and the MF P60 dropin. The main issue I see with the TIR is that it is easily scratched. Time will tell how well it wears.

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I like this range of lights your turning out, real nice little smoothies. 8)

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wow, I like your lights very much. and especially the clicky side style of your lights is so nice!

(and now I want a lathe as well, and loads of spare time to make stuff)

4

Nice.
Would be interested in how hot it gets, and how rapidly.

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that’s some beautiful machining you’ve done there, very impressive. If you don’t much care for the TIR optic you have (which one is it?) I’ve just tried out one of the 10deg XM-L optics from LED-DNA and I’m very impressed. QUite a torch like beam, but with a nice wide hotspot and smooth even spill. It’s noticeably brighter than other 20mm TIR optics too.

6

That awesome. All these customs are making me jealous!

Great work!

7

That's a beauty.

Nicely done, and very creatively implemented !

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WoW I got to get a lathe

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:slight_smile:

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Thanks for the words of inspiration.

This is the TIR here. It says its glass but I could be wrong but feels like plastic to me. When its apart next I will have to take a file to it.

http://fancyflashlights.com/goods.php?id=45

11

Awesome work on this!!

@MattTheMuppet

If you don’t much care for the TIR optic you have (which one is it?) I’ve just tried out one of the 10deg XM-L optics from LED-DNA and I’m very impressed. QUite a torch like beam, but with a nice wide hotspot and smooth even spill. It’s noticeably brighter than other 20mm TIR optics too.

I totally agree with you. Far better than the Carclo units I've always used in the past. It also looks like Ric/CNQG is selling the identical TIR optics. ;)

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They are plastic. Chinese call all of them glass, but they are all plastic.

Really sharp looking light and great machining, you guys make me sick.Tongue Out

Seriously, very nice, but you need to add 4 more 7135 chips to that bad boy!

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neat! Looking forward to the beamshots :slight_smile:

yup, those look exactly the same. Good price, although LED DNA might be cheaper if that’s all you’re ordering (they were $4 + free shipping IIRC). They rate as the easiest optics I’ve ever used - they have a nice interference fit, so all they need is a dab of glue of some sort to keep it in place. They work well with XP-G2 LEDs too by all accounts, just with a narrower spot.

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[/quote]
neat! Looking forward to the beamshots :slight_smile:

yup, those look exactly the same. Good price, although LED DNA might be cheaper if that’s all you’re ordering (they were $4 + free shipping IIRC). They rate as the easiest optics I’ve ever used - they have a nice interference fit, so all they need is a dab of glue of some sort to keep it in place. They work well with XP-G2 LEDs too by all accounts, just with a narrower spot.
[/quote]

So these ones are glass? What is the difference between plastic and glass in light output?

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Thanks Old-Lumens. I need to add 4 more chips aye. I was thinkinking along the same lines but it is coming up to summer and total fire bans are strictly enforced here.

Seriously though I would be doing good if I could add 1 more chip without causing damge. I have a hard enough time getting the wires soldered on. I have solder and flux on order that Match recommended. There will be no excuses then.

As a side note, you are to blame for me trying this lens after your use of them in your flashlights of choice. Sealed

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Blame me? It's ok. I have big shoulders, although they slope down hill a lot more than they used to, but the rain slides off better that way and the S**t too, LOL.

I've used those optics on the Nichia leds and they were very nice. I haven't used them on an XM-L. It will be interesting to see how they fare. On the XP-E they were less than useable as is and I had to frost them, to get the beam smooth and round.

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Great work, MRsDNF! I'm really digging that tailcap design, and awesome work machining the shiny bits!

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Thanks Match. I forgot to mention that the aluminium used was 6061 so hopefully will avoid the scuffs reasonably well. The aa one made from the alloy bike handlebar is wearing extremely well.

Ok. Now for my worst nightmare. I was so careful soldering the wires on the driver making sure that the solder did not connect to anything else and after offering another chip up to solder on and then decided no, I don't want to bugger it up, even tested the driver before soldering it into the pill, all was good. assembled it all together with excited anticipation, clicked it on, it works, go to change modes, yep I've stuffed something up. Works good on high but medium is jittery and no low. Blkjbn ;sfiouhv';oeahn;iwbdfpighev'oji. Can some one please PM me some electronic/soldering skills. I can PayPal if that's ok.

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all TIR optics AFAIK are plastic. I couldn’t guess as to how efficient they are, but they’re as efficient as if not better than TIR optics from Ledil.

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Beeeaautiful light, some people just have it, and, well, others (me) dont… Received yesterday a pack of those 10degree xml optics from ric/CNQG, I like them a lot. The beam is much nicer than a reflector imo, ofcourse it doesnt have the ultimate throw but compared side by side its not far short of a op P60, but that doesnt matter so much, its medium to close range that i find the most useful, my thrower light only got used once in the past year! Still keep it on my bedside cabinet though just incase. I would say they are as efficient as a reflector, it actually seemed to light the room up better than the p60 reflector but that might have just been wishful thinking. I’m getting a right snob, TIR and 4500k led’s all the way. edit: forgot to say, only took 8 days to the uk! Sorry for going off topic. Still drooling…