FmC's DIY Handbuilt thread. Finished!!! It's Alive!!!!!!!

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FmC
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FmC's DIY Handbuilt thread. Finished!!! It's Alive!!!!!!!

p=. I'm planning to do a running commentary with this, & will add 'chunks' of the build as I progress. Right.... let's have a look at the beginnings of what may actually become a working flashlight & even look half decent. I really didn't want to buy anything specifically for this build - I should have enough crap around the house to cobble something together. *+The host contenders+* - These were spotted by me whilst sitting on the lounge, drinking a few beers, & watching Top Gear. Up until then, I had no idea what I would use for a host. Image Hosted by ImageShack.us
I currently have no proper work-bench - I have just had a shed built in the back yard, & have not 'moved in' yet. Pretty much all work will be carried out here in front of the PC, or on the back pattio if it's going to be too messy... I have a myriad of hand tools, but most of them are used for building houses, or working on cars... Image Hosted by ImageShack.us
Hmmm... I think I'll start with the bastard file; Top comes off; Image Hosted by ImageShack.us
Push out the guts; Image Hosted by ImageShack.us
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This should give me enough room now - just have to figure out how to join them neatly; Image Hosted by ImageShack.us
____ *+Reflector & Pill+* I really didn't want to go with a P60, as it seemed too easy. But making a decent reflector by hand, with _those_ tools - nahhh - I think I'll go with a modified P60 reflector & custom pill. Let's see if it fits to start with... Image Hosted by ImageShack.us
Yep, that'll do nicely. Finally, I found some copper, & a nice chunk of it, too; Image Hosted by ImageShack.us
Just have to get it out of that heatsink first... where did that bastard file go??? Cut down the P60 skirt w/hacksaw, + copper slug ready for a date with the drill; Image Hosted by ImageShack.us
Holes drilled with hand drill - (I know it's sitting there in a drill press vise, but it's the only vise I have available...) + tapping holes for the emitter plate retaining screws; Image Hosted by ImageShack.us
Pill topside looking good, along with the much-hated V10 "5 amp" ramping driver that doesn't really do 5 amps... Image Hosted by ImageShack.us
Image Hosted by ImageShack.us
To house the driver, I'm using one of three brass 'C8' pills that have been gathering dust for a while, seeing as they are yet to actually fit any C8's that I have come across... I filed the top flat, sanded, then soldered to the underside of the copper slug. Image Hosted by ImageShack.us
Image Hosted by ImageShack.us
....which brought me to my first hurdle. & there's no switch in that stack yet either... It may have solved a dilemma I was having; whether to have it open at the center, or at the tail. I _may_ have to take a trip to the hardware/plumbing store...

Edited by: FmC on 08/22/2015 - 17:41
FmC
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*+Body.+* With the last episode ending in a slight hiccup, I ended up doing the 'walk of shame' through the plumbing section of the hardware store, but I wasn't liking anything there; any of the threaded fittings that would allow a 26650 battery through the inside were too 'chunky' in proportion to the rest of flashlight body, & would look too out of place. I must have spent about 45 mins. walking around the store, with a 6" steel ruler that I borrowed from the tool isle in order to measure the fittings. Finally, I discovered -gold- brass in the gardening section in the form of this slim-line, fine threaded hose-joiner; Image Hosted by ImageShack.us
...I also coughed up the $3.90 for the stainless ruler... The brass fitting was sectioned with a hacksaw – at this stage I still hadn't decided how much of it to use. It was difficult to think straight with the drill press mocking & taunting me.... '_use me, uuuussse meeeee..._' Image Hosted by ImageShack.us
Image Hosted by ImageShack.us
The body sections had taken a bit of a beating with all of the work & trial fitting so far, so before joining them, some panel work was required to get the two mating ends looking good; Image Hosted by ImageShack.us
The base of the body was rolled back on itself to give a little more strength; Image Hosted by ImageShack.us
The end cap was soldered to the body by heating up the brass cap with a mini butane torch; Image Hosted by ImageShack.us
Image Hosted by ImageShack.us
Inevitably, the base of the tube took a little heat, but it cleaned up alright; Image Hosted by ImageShack.us
Image Hosted by ImageShack.us
The screw-in cap will still need some work to get the switch into it...maybe next weekend... I decided to go with the stream-lined body, rather than having an external joiner, so I rolled up some of Racr86's left-overs from his build & used it as an internal sleeve, epoxying the two halves together; Image Hosted by ImageShack.us
Image Hosted by ImageShack.us
Image Hosted by ImageShack.us
Everything will load in from the tail of the light, & eventually be sandwiched together. *+Additional Pill/Heatsink work+*; To help the heat distribution & transfer to the body, I added a 1mm (.040") copper sleeve to the pill. The assembly is now a tight fit into the body tube. Copper sheet; Image Hosted by ImageShack.us
Rolled up; Image Hosted by ImageShack.us
Soldered to pill; Image Hosted by ImageShack.us
The sleeve also keeps the battery nice & centered. ***A big thanks to Steve from work for providing the copper plate*** Beer

FmC
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*+Switch Assy+*; The threaded fitting was cut down, allowing for a recess for the switch to fit into; Image Hosted by ImageShack.us
Attached some solder wick to the brass, then to one of the legs; Image Hosted by ImageShack.us
Finished switch assy., epoxy'd in place; Image Hosted by ImageShack.us
*+Components+* Here's everything all laid out; Image Hosted by ImageShack.us
*+Assembled torch+*; Image Hosted by ImageShack.us
Image Hosted by ImageShack.us
Image Hosted by ImageShack.us
*It's alive!!!* Image Hosted by ImageShack.us
Image Hosted by ImageShack.us
Image Hosted by ImageShack.us
Some outdoor beam shots; Low; Image Hosted by ImageShack.us
Medium; Image Hosted by ImageShack.us
High; Image Hosted by ImageShack.us
Lux reading @ 1m; 123k Tools used; * Hacksaw * Bastard file * Hand-cut file * Hand drill for pill holes * Hand tap for pill threads * Mini butane torch for soldering the bigger pieces * Soldering iron * Vice * 220 grit sandpaper * Scissors * Hammer * Screw driver * Socket extension for rounding edge ...I think that's all of them... Thanks for reading!!

Old-Lumens
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Holy Shite! That is just Awesome!

My PayPal address: oldlumens (insert the @ sign here) gmail.com

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MRsDNF
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As OL said. Now thats thinking outside the box. Very impressive start.

 

djozz quotes, "it came with chinese lettering that is chinese to me".

                      "My man mousehole needs one too"

old4570 said "I'm not an expert , so don't suffer from any such technical restrictions".

Old-Lumens. Highly admired and cherished member of Budget Light Forum. 11.5.2011 - 20.12.16. RIP.

 

Foy
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I'm going to tell you right now, this is damn cool and I am very interested to see how this turns out.

 

Foy

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ryansoh3
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So cool that Foy had to repeat himself three times. Big Smile

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relic38
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Awesome idea FmC! You are way ahead of me. I will not even get started this week. Sad

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michaeljee
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Nice surprise about this shorter form. Can you tell us what it is you are talking/writing about?
Has any info. about this shorter form been posted before (and i just missed it)?

FmC
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Thanks for the comments.

I got a little more work done on the pill assy., will update the build log later today.

mattthemuppet
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wow, that’s some out of the box thinking going on there!

A sleeve with some kind of twist and latch/ peg’n‘hole set up might help join the 2 halves together and allow you to change the battery. The solution to the switch mystery is going to be interesting Big Smile

PyTech
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Wow! great stuff

-Sean

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Great start!

Buwuve
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This is a great idea. A battery body. Can't wait for more Smile

Light up the darkness.

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very unique and cool factor.

FmC
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Thanks guys.

mattthemuppet wrote:
A sleeve with some kind of twist and latch/ peg’n‘hole set up might help join the 2 halves together and allow you to change the battery….

Yeah, I was thinking along those lines, unless I can find a threaded solution that is thin enough to be inside the ‘body’, yet still have enough i.d. for the battery to pass through.

Rufusbduck
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Clever!

Three Tanna leaves to give him life, nine to give him movement. But what if he eats the whole bag?

Scott

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I’m amazed of the nice builds I’m seeing this week, the idea of the contest was great!

Mooooooo

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I may have sorted the length problem & the tailcap assy. at the same time.

2nd post updated.

MRsDNF
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I hope you got a discount on the ruler as it was used. Its amazing what you can find if you look hard enough. The nuts even come complete with knurling. Now thats got to be worth an extra couple off points.

 

djozz quotes, "it came with chinese lettering that is chinese to me".

                      "My man mousehole needs one too"

old4570 said "I'm not an expert , so don't suffer from any such technical restrictions".

Old-Lumens. Highly admired and cherished member of Budget Light Forum. 11.5.2011 - 20.12.16. RIP.

 

troisanh
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wow you guys cant stop to amaze me with your ideas!

panthervision23
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The part that amazed me the most is the way you modified the batteries. J)

FmC
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Done a little more work this w/end, not as much as I would have liked, due to family commitments.

2nd post updated with new progress.

MRsDNF
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Coming along nicely FmC. It looks like coke cans are the flavour off the month in mods.

 

djozz quotes, "it came with chinese lettering that is chinese to me".

                      "My man mousehole needs one too"

old4570 said "I'm not an expert , so don't suffer from any such technical restrictions".

Old-Lumens. Highly admired and cherished member of Budget Light Forum. 11.5.2011 - 20.12.16. RIP.

 

mattthemuppet
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that’s some very neat work you’re doing there! Coke can’s are awesome, they’re useful for all kinds of things.

relic38
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That is looking quite nice! Great job FmC. Maybe I should start my build soon…

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Rufusbduck
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Great find on the brass. I can hear it now “ can I help you sir?”, “no thanks, just looking”. No idea how many times I’ve wandered the isles looking for “I don’t know what”. Borrowed my share of tape measures too.

Three Tanna leaves to give him life, nine to give him movement. But what if he eats the whole bag?

Scott

MRsDNF
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Rufusbduck wrote:
Great find on the brass. I can hear it now “ can I help you sir?”, “no thanks, just looking”. No idea how many times I’ve wandered the isles looking for “I don’t know what”. Borrowed my share of tape measures too.

I’d suggest to find another shop if they don’t supply customer service. Whoever heard off a plumbers supply not helping you find the fitting that’s just right to build flashlights with. Whats happened to this world. Unbelievable.
Still watching. Smile

 

djozz quotes, "it came with chinese lettering that is chinese to me".

                      "My man mousehole needs one too"

old4570 said "I'm not an expert , so don't suffer from any such technical restrictions".

Old-Lumens. Highly admired and cherished member of Budget Light Forum. 11.5.2011 - 20.12.16. RIP.

 

relic38
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Mine went something like this:
“Can I help you sir?”
“Yeah, I’m looking for a threaded adapter in copper that I can use for a flashlight head”
[blank stare] “OK, well everything we have in copper [starts backing away] is in this aisle, so if it’s not here [raises voice due to distance] we do not have it.”
“Sure, no problem, thanks!”

After that, now I just say what RBD says Big Smile

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Rufusbduck
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Yeah, lesson learned. Now I put on my stupid face and say “nope” whenever they ask. I like the way this is turning out and the tricks you use.

Three Tanna leaves to give him life, nine to give him movement. But what if he eats the whole bag?

Scott

texaspyro
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relic38 wrote:
“Can I help you sir?”

When I get asked that question, I just start drooling and twitching and blurt out “they have tried…”

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