DBCstm handmade build... Finished Light w/stand end of thread 6-21-13

136 posts / 0 new
Last post

Pages

DB Custom
DB Custom's picture
Offline
Last seen: 23 hours 14 min ago
Joined: 01/13/2013 - 22:28
Posts: 20698
Location: Heart of Texas
DBCstm handmade build... Finished Light w/stand end of thread 6-21-13

Ok, I’m in. I have no idea if I can pull this off but I’m game. But I need to check a bit on some basic rules. Tabletop drill press is out, correct? But a cordless drill and dremel tool are ok? This should work ok for me, as the El Crapola benchtop drill press I have would ruin things if I tried to use it. Ask me how I know lol.

Also, is there a plan for the lights after they’re built? I’d like to gift this one to my neighbor who’s generously supplying the basic raw package without really having a clue what is going to become of it. He’s a L.E.O. and into WWII era paraphernalia so it’d only be fitting, if I’m successful, to gift it back to him.

So, all this said, here’s my “package”
DBC_October 24, 2012_190212 is

The one on the left. Well, sorta. This one’s a dummy round with holes in the cartridge. The real one will be a fresh brass cartridge with shiny copper bullet. The MBI HF in Cu is for size comparison.

The Plan: Pull the bullet from a live .50 cal round. This will be turned down slightly to allow it to slide in the neck. It will be attached to a McClicky switch and the copper bullet will be the on/off clicky itself. I plan to cut the cartridge to gain access to load optics/emitter/driver/cell. Will rig a thread into the cartridge, probably just under the necked portion, to allow battery changes. Open up the primer end, after firing the primer and removing it of course, for a TIR optic on a XP-G2 relowed to Nitro’s copper star with a 1/4” copper heat sink behind it, driven by, well we’ll see. I have a driver in mind that should run the emitter at 1.4A with 3 modes with memory and low-discharge protection. So if it works out, it’ll be running something like 250 lumens on high (OTF), and look like a live .50 cal round when standing inert.

Oh boy, I think I’m in over my head! Smile

Edit: So I figured out how to pull the bullet from a .50 Cal round. I formed 2 pieces of 12ga copper wire to fit into the retractor slot of the base on the cartridge. Then found a pipe of the correct diameter for the bullet to fit into such that it would press the copper pieces into the retractor slot to act like a collet. Then some serious banging on a large piece of steel and the bullet was dislodged by inertia. A bit scary, that part! But here ya go…the body.
DBC_June 11, 2013_111449

Beside the BBC 261L (cause I just really love looking at it!) and the 14500 cell I plan to power the light with.

Edited by: DB Custom on 06/22/2013 - 00:41
DB Custom
DB Custom's picture
Offline
Last seen: 23 hours 14 min ago
Joined: 01/13/2013 - 22:28
Posts: 20698
Location: Heart of Texas

First thing was to get the prime out and start preparing for an TIR Optic. This sounds easy but the primer is this bad boy was equally stout! I think this is a Berdan primer, instead of an anvil in the primer cup, a post is machined in the casing itself with a charge hole on either side. This post made a drill bit want to slip off center, so I had no choice but to dremel it out.
DBC_June 11, 2013_160902-2

This one lets you see the post better. The dark or black is the bottom of the primer hole where the spent powder burned the brass. Of course, the primer had to be discharged after pulling the bullet in order to get going on this build.
DBC_June 11, 2013_162131-2

A bit better look at the reamed out primer cup hole with the pinch post still standing but a bit worse for the wear
DBC_June 11, 2013_162223-2

A nice little pile of brass shavings and some toasted fingers later…
DBC_June 11, 2013_165818-2

Ahh, who would have thought the base of a .50 Cal round would have 5/16” of brass under the primer? Hopefully that’s the worst of it, we’ll see! Wink

Plan to reflow the emitter on a Nitro copper star today, we’ll see if I have to turn that down to fit…my luck, probably so. lol

When discussing building this with my neighbor, Steve, I was thinking to make the copper bullet a twisty action to turn on the light. He thought it’d be cool to make it the pushbutton for a clicky. So this is what I’ll be attempting, provided I can get a clicky switch inside of course. So once again, I might have to do some fancy footwork on virtually every component to pull this off. And once again, I am thinking I may be in over my head! I’m a photographer, not an engineer, but hey, how hard could it be?

New pics 6-13-13 Step 2: Body prep

The build ingredients, XP-G2 R5 2B emitter, Ledil Tina2 RS TIR Optic, McClicky switch and potentially this 10mm driver with 1.4A 3 mode…might change that to a 3.04A Q-Lite driver.
DBC_June 12, 2013_125700-2

I cut the cartridge to start working the insides…
DBC_June 12, 2013_175555-2

Finished up the external mount for the TIR
DBC_June 12, 2013_185904-2
DBC_June 12, 2013_200614-2

And got the TIR fitted…
DBC_June 13, 2013_112708-2

New Pics 6-13-13 PM Step 3, 4, 5 The Pill

I got busy today and made some good progress. Had to square up the inside of the “head” section, while the cartridge tapered up on the outside, it tapered down on the inside to form a bowl with very thick walls at the platform. So I squared that up, then worked my tail off cutting a rough circle in a 1/4” bar stock (This stuff is hard, it was a bus bar in the telephone company back in the 50’s) Then had to file it down to get it close then finish with sanding using a glass table top to keep it square, so I could get it round! Smile Then cut a piece of 3/4” copper pipe and fit it so that it’d make a shelf for the driver. Whew!

The squaring of the head…
DBC_June 13, 2013_161816-2

The parts…
DBC_June 13, 2013_161910-2

1/4” thick copper heat sink, with copper shelf for driver…
DBC_June 13, 2013_161740-2

Testing fit..
DBC_June 13, 2013_161703-2

Bird’s eye view, looking down inside the “head” which is of course the bottom of the .50 Cal cartridge…
DBC_June 13, 2013_162102-2

My fingers are about wore out! I held that little slab of copper in my fingers the duration of filing and sanding it down, hand work never got more manual than this! The rest can wait til tomorrow…

Step 6, Body and Pill assembly

Ok, today I went to town and studied the plumbing section at Lowe’s very carefully. Ended up with a 1/2” compression fitting. Cut the threads out of the fitting and put them in the light, sounds easy, right? LOL Then I put the pill together, and it checks out perfectly! I’m using the Q-Lite 3.04A 3 mode driver with the XP-G2 R5 2B emitter glued to a slab of copper. Smile

The threads…
DBC_June 14, 2013_171644-2

These will still have to be glued in, but that has to wait till the pill is dry as well as the TIR, which is glued into the head from the outside…
DBC_June 14, 2013_171738-2

Pieces fit together and thread up quite nicely, a very snug compression fit with zero room left for adjustments…
DBC_June 14, 2013_171823-2

I’ll work on the visible line and finish when I get everything fitted and working. The “head” has been handled a lot, so it’s taken a bit of a polish from handling…
DBC_June 14, 2013_172020-2

Between this chunk of copper and all the surrounding brass, heat should have no problem figuring out where to go…
DBC_June 14, 2013_191519-2

The Q-Lite driver in the pill. I’ll have to ream out the male threads a little more, an Alkaline AA fits easily but a Protected AW14500 doesn’t.
DBC_June 14, 2013_191626-2

And it’s time for today’s installment of alcohol. Smile But I’m very happy with progress, and it feels good! Wink

Step 7, Fitment and testing

So, it’s supposed to work something like this…

DBC_June 15, 2013_130159-2

DBC_June 15, 2013_130244-2

DBC_June 15, 2013_130331-2

No, it’s not finished, but it works! Smile

Step 8, Finish

And now that it’s fully assembled, with it’s batteries on the way, it gets a polish. Let’s call it Gunner’s Dress Blues .50 Browning Machine Gun or GDB .50 BMG for short.

GDB .50 7L

GDB .50 7LII

GDB .50 8L

I need to do some tweaking on the overall inside length, but have to wait for the correct batteries to get here for that. The AW and Intl-Outdoor cells are protected and longer than standard, so I will probably create a copper spacer to allow those to work as well.

Happy Father’s Day!

Step 9

Improvised a work-around to use the cells I have on hand, temporarily. This enabled some working pics. AW IMR 14500 cell should be here in the next couple of days so I’ll get full working amperage readings then and possibly take some more pics. But til then, enjoy!

GDB 50BMG 16L

GDB 50BMG 31L

Beamshot settings set up for the medium level to show difference in beam modes.

GDB 50BMG Beamshots

Not too shabby! Wink There’s a dark artifact in the center that’s barely visible that really puzzles me, other than that, it’s a whole lotta light!

To bring some of the finished pics from the end of the thread to conclude this build, here’s the way it ended up:

With the AW IMR14500 in the light, it closes completely when on for a near seamless finish. I added a copper wire bypass in the spring on the driver to get a 2.82A reading off this cell. And to finalize it, I created a stand to give the light a “Rocket Ship” look when on the shelf. Smile

DBC_June 21, 2013_233002

And for posterity, this “poster”…

GDB50BMGSupernova

A real fun challenge, Thanks Old-Lumens, brilliant idea!! Smile

totilde
totilde's picture
Offline
Last seen: 1 year 10 months ago
Joined: 12/27/2012 - 12:22
Posts: 1157
Location: spain

good idea, looking forward to seeing it finished (i like the rusty finish, maybe you should make both shiny and rusty versions!)

Mooooooo

Rufusbduck
Rufusbduck's picture
Offline
Last seen: 1 year 8 months ago
Joined: 04/04/2012 - 15:34
Posts: 10389
Location: Golden state

That’s Tacticool!

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

Scott

Pulsar
Pulsar's picture
Offline
Last seen: 4 months 3 days ago
Joined: 07/29/2011 - 00:41
Posts: 5840
Location: Maine

good idea! cant wait to see that .50 cal loaded up

Old-Lumens
Old-Lumens's picture
Offline
Last seen: 3 years 11 months ago
Joined: 11/04/2011 - 11:39
Posts: 7478
Location: Tyler, TX, USA

Yes a drill press is out. Another very unique start! This is really going to be a hard contest to judge. I love it!

No plan for the lights. I was hoping they would be gifted to someone or in a giveaway here, but it's up to each contestant what they do with them.

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

My YouTube Flashlight Video Channel

The BLF Modding Links Thread 

http://imageshack.com/a/img922/1374/jQ2wdL.jpg

 

DB Custom
DB Custom's picture
Offline
Last seen: 23 hours 14 min ago
Joined: 01/13/2013 - 22:28
Posts: 20698
Location: Heart of Texas

I had my neighbor, the cop who supplied the .50 Cal round in the first place, assist me with the disassembly of said round. Told him what I was planning on doing and he’s really interested…“if it works out, I’m gonna have to get you to build me one!” lol

I’m putting it on “paper” that it’s going back to him when done, so that I won’t even think about keeping it for myself! Smile Gonna be hard to part with after all the work, I’m sure.

So now that I have the components, sans propellant, I can start trying to get it all assembled. The fun part! Wish me luck! Wink

kronological
kronological's picture
Offline
Last seen: 2 years 11 months ago
Joined: 12/12/2012 - 09:23
Posts: 3042
Location: Texas

Steve McQueen would be proud :bigsmile:

No one, after lighting a lamp, puts it away in a cellar nor under a basket, but on the lampstand, so that those who enter may see the light.

My Reviews: Ma

MRsDNF
MRsDNF's picture
Offline
Last seen: 4 hours 59 min ago
Joined: 12/22/2011 - 21:18
Posts: 13456
Location: A light beam away from the missus in the land of Aus.

Nice DBC. Weren’t rules made to be broken?

 

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.

 

RaceR86
RaceR86's picture
Offline
Last seen: 4 years 9 months ago
Joined: 02/22/2012 - 08:32
Posts: 3777
Location: Norway

Sweet!
This is genius!

BLF LED database – collaboration spreadsheet and latest news about where to buy LEDs
http://budgetlightforum.com/node/19342

Pulsar
Pulsar's picture
Offline
Last seen: 4 months 3 days ago
Joined: 07/29/2011 - 00:41
Posts: 5840
Location: Maine

thats what i was thinking... just have a 3" head machined out of copper and all pieces threaded, and claim i did it by hand with a precision file Innocent

DB Custom
DB Custom's picture
Offline
Last seen: 23 hours 14 min ago
Joined: 01/13/2013 - 22:28
Posts: 20698
Location: Heart of Texas

The “rusty version” is a dummy round, made without the Berdan primer pocket and with 3 holes in the cartridge case. Probably made for training purposes to simulate actual weight and feel. So, it’ll be a polished brass case with polished copper bullet. Speaking of the bullet that thing is massive! There’s enough lead in there to balance a truck wheel! lol Thinking that I’ll remove the lead to lighten the load, we’ll see. Might melt the lead out of the copper bullet, then fill it with JB Weld mixed with the brass that came out of the primer pocket, this would give it extra strength for drilling and tapping to put a bolt in it for…but I digress…

I thought if I had it made at the machine shop down the road, then marked it up a bit with the “precision file” it’d be all right? No? LOL. This one’s gonna be difficult all the way it appears. That would have to be the case, of course, for my 1st attempt. Wink

We’ve got til October to finish this, don’t we?

And only gimped up Aussies are allowed to break the rules, ROFLMAO

MRsDNF
MRsDNF's picture
Offline
Last seen: 4 hours 59 min ago
Joined: 12/22/2011 - 21:18
Posts: 13456
Location: A light beam away from the missus in the land of Aus.

Looking good. I’ve never seen a 50 calibre round but if you go to youtube, they certainly pack some recoil.

 

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
Foy's picture
Offline
Last seen: 5 years 7 months ago
Joined: 01/02/2011 - 17:56
Posts: 3009
Location: Las Vegas

Government brass will almost always have two holes in the primer pocket and the primer is crimped, I think.  Not just pressed in like us civvies do.  Foy has pressed a lot of ammo over the years and I don't even bother with military brass.

 

rockchuckerFoy

No referral links and nothing embedded . . . ever.

                      &nbsp

texaspyro
Offline
Last seen: 1 year 4 months ago
Joined: 04/29/2011 - 12:43
Posts: 4593

You are making things too hard on yourself. If you had just whacked the primer with a hammer/nail, you could have killed (at least) two birds with one stone… the primer would then be inert and the bullet would have removed itself. J)

Rufusbduck
Rufusbduck's picture
Offline
Last seen: 1 year 8 months ago
Joined: 04/04/2012 - 15:34
Posts: 10389
Location: Golden state

Probably three birds, maybe more. I like your pics better than mine.

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

Scott

DB Custom
DB Custom's picture
Offline
Last seen: 23 hours 14 min ago
Joined: 01/13/2013 - 22:28
Posts: 20698
Location: Heart of Texas

The TexasPyro way would have added me, the cop and his son to birds killed! Silly

The primer cup was a byat*h to get out. Then the strike post was very solid as well. But that’s all done and the TIR is fitted, sitting slightly recessed into the casing. Wink

Thanks RBD, still using the point-n-shoot, will break out the big guns when it’s finished (if that happens)

Have more pics, not at my computer. Will update later today.

Old-Lumens
Old-Lumens's picture
Offline
Last seen: 3 years 11 months ago
Joined: 11/04/2011 - 11:39
Posts: 7478
Location: Tyler, TX, USA

DBCstm wrote:
And got the TIR fitted... DBC_June 13, 2013_112708-2

That is really something else. I am so glad you guys took up the challenge. We are getting to see some great ideas!!

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

My YouTube Flashlight Video Channel

The BLF Modding Links Thread 

http://imageshack.com/a/img922/1374/jQ2wdL.jpg

 

Chicago X
Chicago X's picture
Offline
Last seen: 7 years 5 months ago
Joined: 07/22/2011 - 16:13
Posts: 4013
Location: See Name

texaspyro wrote:
You are making things too hard on yourself. If you had just whacked the primer with a hammer/nail, you could have killed (at least) two birds with one stone... the primer would then be inert and the bullet would have removed itself. J)

 

http://wardogsmakingithome.org/index.html

War Dogs, Making it Home - Rescue Dogs for Returning Vets

DB Custom
DB Custom's picture
Offline
Last seen: 23 hours 14 min ago
Joined: 01/13/2013 - 22:28
Posts: 20698
Location: Heart of Texas

…wait for it….

Discharged!

Smile

Thanks O-L, prec8 it.

MRsDNF
MRsDNF's picture
Offline
Last seen: 4 hours 59 min ago
Joined: 12/22/2011 - 21:18
Posts: 13456
Location: A light beam away from the missus in the land of Aus.

I love your parting off tool. Its not dissimilar to mine except mines a 9’‘ version. To hold the TIR in, if you have a small enough cut off disc you can cut a groove with it and insert a round piece if wire. I found the large spring off P60 pills work great cut to the right length.

 

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.

 

DB Custom
DB Custom's picture
Offline
Last seen: 23 hours 14 min ago
Joined: 01/13/2013 - 22:28
Posts: 20698
Location: Heart of Texas

Neat idea, was planning on gluing it in for the seal. To do the ring, I’d have to inset the TIR that much further, and THAT would not be easy! The deeper inside that taper cut goes, the more difficult it is to cut without getting into the top squared cut. I found a tool today that might work for that, would have to resize the tool’s diameter but I’ve been making tools along the way so what the heck! lol My metal cutting hole saw is missing it’s mount. So I had to find a fine thread bolt that would fit it, clean the threads on that with a NuTrix thread file, cut the hex head down to round to fit inside the 7/8” hole saw, then cut notches in the side of that now round head to enable me to get needle nosed pliers on it to tighten it inside the hole saw. This, so that I could mount it in my cordless drill. Did I mention it’s 105º? Might’ve lost a few pounds today, it’s 95 on the back porch where I’m working, doing all this on a patio table with a glass top. Uh, It’s, well, kind of a mess at the moment. Smile

We live in the country, it’s a solid 45 minute trip to town and back, if I can find the part I need in one stop. So I improvise. Hate buying a tool for a job that I’ll use once. Or may not use again for years, ya know?

My Dremel tool was bought in 1995, I have no idea what I’d do without it.

Pics added to post #2 of today’s work, y’all have a good evening/day/whatever (I’ll be toasting y’all with a drink this PM for sure!) Smile

MRsDNF
MRsDNF's picture
Offline
Last seen: 4 hours 59 min ago
Joined: 12/22/2011 - 21:18
Posts: 13456
Location: A light beam away from the missus in the land of Aus.

Just talking to myself again and thought if the spring was to big in wire diameter a key ring of the right diameter cut would do the same thing with a tiny groove. Its lookin good. To pitch in for your effort l’ll help you out and have a few ales as well. Beer

 

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.

 

DB Custom
DB Custom's picture
Offline
Last seen: 23 hours 14 min ago
Joined: 01/13/2013 - 22:28
Posts: 20698
Location: Heart of Texas

You’re all heart! Bottoms up!

Rufusbduck
Rufusbduck's picture
Offline
Last seen: 1 year 8 months ago
Joined: 04/04/2012 - 15:34
Posts: 10389
Location: Golden state

I’ll bring the popcorn.

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

Scott

Pulsar
Pulsar's picture
Offline
Last seen: 4 months 3 days ago
Joined: 07/29/2011 - 00:41
Posts: 5840
Location: Maine

Wow! Great job and great progress. That is going to be a truly amazing mod

DB Custom
DB Custom's picture
Offline
Last seen: 23 hours 14 min ago
Joined: 01/13/2013 - 22:28
Posts: 20698
Location: Heart of Texas

So I put the pill in the head and glued in the threads. Tested it with my DMM on an AW Protected 14500 and get .05A Low, .65A Med, and 2.16A on High. Reasonable numbers for that cell, and probably better for the emitter than 3A.

Edit: How about .05A Lo, .75A Med, and 2.51A on Hi with an Efest 10440 cell. Smile

ruffles
ruffles's picture
Offline
Last seen: 2 days 8 hours ago
Joined: 07/09/2011 - 10:18
Posts: 1020
Location: California

Awesome, awesome, and awesome! I’m impressed by everything, but the threaded connection is particularly sweet. Keep at ‘er!


 

DB Custom
DB Custom's picture
Offline
Last seen: 23 hours 14 min ago
Joined: 01/13/2013 - 22:28
Posts: 20698
Location: Heart of Texas

Much appreciated.

Rufusbduck
Rufusbduck's picture
Offline
Last seen: 1 year 8 months ago
Joined: 04/04/2012 - 15:34
Posts: 10389
Location: Golden state

Wow! Great job centering the parts. I feel your pain, many’s the hour I’ve spent sanding and filing but that’s what hand work is. :~ I see the finger saving drill powered sanding reamer there. A lifesaver if you ask me. :bigsmile:

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

Scott

MRsDNF
MRsDNF's picture
Offline
Last seen: 4 hours 59 min ago
Joined: 12/22/2011 - 21:18
Posts: 13456
Location: A light beam away from the missus in the land of Aus.

I hope people dont get sick off me saying amazing. I love your way off thinking outside the square with your way off threading this light together. This is coming together very nicely for you Arn, sorry, DBCstm. Your right. It is drink oclock. Cheers again.

 

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.

 

Pages