BTU Shocker Mod - XM-L2 U2's/SinkPAD's

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Tom E
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BTU Shocker Mod - XM-L2 U2's/SinkPAD's

Just briefly here - upgraded a BTU Shocker to XM-L2 U2 (1A -1C or so) for rdrfronty, nice results. Please note it has an AR lens installed:

On Panasonic PD's (FT) w/magnets on neg. end, fresh: 3,760 lumens @30 secs

On KeepPower 3400 KumaBears, fresh: 3,644 lumens @30 secs

On same set of KeepPowers from above after 1 min of time on batteries: 181 kcd

This thing is scary, a true beast to be afraid of.

 There may be a few Q's coming, but these numbers I feel pretty confident in from previous lightbox measurements (many), though I know it's not a perfect setup for sure. Also, the lumens was actually rising a little during the first 30 secs, then settles at about 45 seconds, then slowly started dropping off. SinkPAD's are doing their thing, and 20 gauge wire, Arctic Silver 5/Arctic Alumina epoxy, polished surfaces sure helps.

 The only thing I've seen close to this is my mod'ed J18 at 5,000 - 5,500 lumens, but of course no where near the throw of the Shocker.

I'm wondering how much loss is coming from the battery carrier though, and if Pana PD's do that well, how would Samsung 20R's do? Or the new Sony 30 amp batts (short run though Smile)?

rdrfronty
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Absolutely awesome results Tom! That’s something like a 22-23% increase in lumens and a even more in throw. Sounds like you got the focus dialed in nicely too with the big throw increase.
Your attention detail really paid off. And it’s nice to see that it is holding its numbers good, much better than before. Those copper Sinkpads and quality thermal paste are certainly doing their job here.
So you have made an already impressive light that had roughly 2900 lumens and 700m throw, to a even more staggering 3644 lumens and 850m in throw. That’s on Keeppower 3400’s like I usually run it on.
I can’t wait to get this beast back in my hands!

Chicago X
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Nice job !

You guys are going to force me into a Shocker purchase with all of these awesome mod threads. 

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blueb8llz
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Chicago X wrote:

Nice job !

You guys are going to force me into a Shocker purchase with all of these awesome mod threads. 

i know right! this btu might be on my wish list now….unless, hay tom E, can this same mod be done to a fenix tk75?

DayLighter
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blueb8llz wrote:

i know right! this btu might be on my wish list now….unless, hay tom E, can this same mod be done to a fenix tk75?


yeah… that will be very interesting.too bad Fenix glued everything :Sp

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Nice job there Tom E. Its amazing what a small change can do for the big picture.

 

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djozz
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I find it a bit surprising that also the more high end manufacturers fail to do the obvious to get the most out of their designs, what would it cost them, a few dollars on a 100+ dollar light?

comfychair
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djozz wrote:

I find it a bit surprising that also the more high end manufacturers fail to do the obvious to get the most out of their designs, what would it cost them, a few dollars on a 100+ dollar light?

What? Who wants to buy something that can't be made better? That would take all the fun out of it.

jmpaul320
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very nice mod tom – i am regretting selling my shocker actually… if you ever want to unload that thing you know ill give it a nice home Smile

Would you mind keeping the wrong flashlight?
Best wish, May
Tmart service team

 

Soumil wrote:

PLEASE HELP ME GEARBEsT! IM LITERALLY CRYING!

 

Tom E
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DayLighter wrote:
blueb8llz wrote:
i know right! this btu might be on my wish list now....unless, hay tom E, can this same mod be done to a fenix tk75?
yeah... that will be very interesting.too bad Fenix glued everything :Sp

Yes - sounds like LockTite sealed for the TK75, but of course, that hasn't stopped us before. I and others did the Crelant 7G9 ( I scratched mine up some), others (_the_ and a couple others) cracked open the TN31. But the TK75 will have it's limits  - smaller reflectors in diameter and depth. It's probably pretty tweaked now, for the XML U2's though - it's an outstanding quality design for it's size.

bibihang
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Where can I buy the AR coated lens that big?

Dale
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bibihang wrote:
Where can I buy the AR coated lens that big?

I got mine from Olight… The SR90 lens fits perfectly. Kudos on the upgrade. I had this done a few months ago. I absolutely love it.

manxbuggy1
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Tom E wrote:

DayLighter wrote:
blueb8llz wrote:
i know right! this btu might be on my wish list now….unless, hay tom E, can this same mod be done to a fenix tk75?
yeah… that will be very interesting.too bad Fenix glued everything :Sp

Yes – sounds like LockTite sealed for the TK75, but of course, that hasn’t stopped us before. I and others did the Crelant 7G9 ( I scratched mine up some), others (the and a couple others) cracked open the TN31. But the TK75 will have it’s limits  – smaller reflectors in diameter and depth. It’s probably pretty tweaked now, for the XML U2’s though – it’s an outstanding quality design for it’s size.

When has a light being a great design ever stopped you from making it even better? Lol. With the smaller head I know the same results as the shocker would be impossible but going XM-L2 U2 on sinkpads could very well net 3500 OTF and 125k cd putting right up there with it’s much more expensive brother, the RC40. If you ever get bored or curious. Just sayin’.

FMcamaroZ28
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What is the MM of the lens? I know a bunch of glass companies that i work with maybe i can get a batch made up!

Tom E
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 Agree bout the TK75, it could made better. For the Shocker, If I had unlimited resources and tools/skills, I'd take weight off that reflector, as much as I could by milling/drilling it down, then replace or layer on top of the pill top a copper heat sink, thicker, integrated tight to the surrounding aluminum. Now you got a framework to work with - great reflector, size, and proper heat sinking. Then you need a driver to go 4.5-5A per LED with boost - no auto step down. 3 18650's won't last too long though, so, extend the body to take another 3 batt carrier, and get a side switch on it. That's All, You're Done! Smile

jmpaul320
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Tom E wrote:

 Agree bout the TK75, it could made better. For the Shocker, If I had unlimited resources and tools/skills, I’d take weight off that reflector, as much as I could by milling/drilling it down, then replace or layer on top of the pill top a copper heat sink, thicker, integrated tight to the surrounding aluminum. Now you got a framework to work with – great reflector, size, and proper heat sinking. Then you need a driver to go 4.5-5A per LED with boost – no auto step down. 3 18650’s won’t last too long though, so, extend the body to take another 3 batt carrier, and get a side switch on it. That’s All, You’re Done! Smile

i like the way you think!

Would you mind keeping the wrong flashlight?
Best wish, May
Tmart service team

 

Soumil wrote:

PLEASE HELP ME GEARBEsT! IM LITERALLY CRYING!

 

rdrfronty
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FMcamaroZ28 wrote:
What is the MM of the lens? I know a bunch of glass companies that i work with maybe i can get a batch made up!

If I remember correctly, about a 95-96mm would be about perfect. The stock one and the SR90 one are both about 93mm. They work ok, but have a fair amount of play.
indenial
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I put this 96mm UCLp AR Acrylic Lens in my BTU with no problems..

My name is indy, and I've been a flashaholic since 2004.

Tom E
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indenial wrote:
I put this "96mm UCLp AR Acrylic Lens":http://www.flashlightlens.com/index.php?app=ecom&ns=prodshow&ref=UCLp_AR in my BTU with no problems..

The 59 mm UCL/p fits both HD2010's and Small sun T08's (got one on each) - I like them, would be better maybe with glass, but flashlightlens doesn't make the big UCL's.

jmpaul320
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beamshots?

Would you mind keeping the wrong flashlight?
Best wish, May
Tmart service team

 

Soumil wrote:

PLEASE HELP ME GEARBEsT! IM LITERALLY CRYING!

 

Tom E
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jmpaul320 wrote:
beamshots?

rdrfrtonty can have the pleasure - I'm backed up here...

jmpaul320
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this is making me regret selling my btu shocker …. but at least it went to dale who did a similar mod haha

Would you mind keeping the wrong flashlight?
Best wish, May
Tmart service team

 

Soumil wrote:

PLEASE HELP ME GEARBEsT! IM LITERALLY CRYING!

 

rdrfronty
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jmpaul320 wrote:
beamshots?

Yep, I’ll make sure to do some beamshots when I get it back. Brother and I just got back scoping out new photo target areas. Found a good spot with good potential for 500-600m shots. A long pipeline right-away cut through a national forest. The path is roughly 25-30m wide I think. Want to do the BTU, SR90 (w/ SBT70), TN31mb, TN31 (xml2 dedomed), TN31 XML2 (on copper), and TK75. Will likely throw in a couple more moderate throwers like 7G5, M3C4, & SR51 for comparisons sakes to the serious throwers. We want to do full distance shots of the 500-600m, and then get perhaps 25-50m from the target to show much better how much light actually makes it there. That way we won’t have to worry about zoom screwing up the long distances. Not sure how much light those last three will get to a target that far, perhaps none, but maybe .1L or so.
So is the plan anyway.
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Very nice! Looking forward to hearing how it stacks up to your other lights now.  8)

tkmckay
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indenial wrote:
I put this 96mm UCLp AR Acrylic Lens in my BTU with no problems..

Thanks for the link… one on order Smile
DayLighter
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the cool thing about Fenix TK75 is .. it can add several battery tube extensions ( Fenix engineers tested up to 9), but it ain’t cheap at $40 a pop, could have bought another light Silly
maybe someone with lathe can create battery tube extension for BTU? Big Smile

 photo fenixtk75_zps9d831169.jpg

The only way to do a great work is to love what you do.

smodtactical
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tkmckay wrote:
indenial wrote:
I put this 96mm UCLp AR Acrylic Lens in my BTU with no problems..
Thanks for the link… one on order Smile

Ordered one as well, thanks.

relic38
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OK, there is definitely something wrong with my BTU. I did the exact same mod and I get much lower throw numbers, even lumens. I think the reflector is bad.
Can someone take a closeup picture of the reflector surface? Mine looks weird. I’ll add a pic in a bit. I want to get to the bottom of this.
For reference, mine is driving 3 XM-L2 U2 emitters on 20mm SinkPads. The driver died, so it’s DD now; at 5.5A! The kicker? I get 115kcd (measured lux at 12 ft and calculated). That’s almost the stock throw, not quite. Makes no sense to me. I’ve tested with the lens out too; only adds 12kcd or so.
Lumens are around 3050 after 30 seconds. Add ~200 with no lens. Still well short of the OP mod, and I’m at 5A+. :~
Edit: Close-up of reflector surface:

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Maybe its not in the reflector but the lux meter differences, or calibration between the two. Are all 3 reflective surfaces scuffed like that, and does that swirl remain uniform throughout the entire surface? Ive had a few reflectors where I could see that someone had cleaned them with a rag and scuffed them, but the swirls were not patterned throughout the entire reflector surface.

Tom E
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relic - oh boy, the Shocker is in transit now so don't have it, but those lines don't look familiar from what I recall. Hhhmmm, I did before/after measurements of the Shocker also, so emitter upgrade seemed to be true. I also did my throw measurement at 4.3 meters, about 13 ft. The good thing is the mod'ed light is going to rdrfronty, so he will do full measurements and more reliable outdoor distance measurements on the throw so we'll get confirmation, good or bad.

 Man, the driver died?? Did you have the original or the Dry driver? That really sucks, sorry to hear these issues. I'm sure rdrfronty could provide some input, but he won't get it til the weekend. Had a small "shipment" of mod'ed lights going his way... Whewwww.

Tom E
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DayLighter wrote:
the cool thing about Fenix TK75 is .. it can add several battery tube extensions ( Fenix engineers tested up to 9), but it ain't cheap at $40 a pop, could have bought another light Silly maybe someone with lathe can create battery tube extension for BTU? Big Smile  photo fenixtk75_zps9d831169.jpg

Yes - that option would be awesome for a Shocker, but man, that TK75 is so well engineered...

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