"D" Mag Mandrel... Image heavy

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TexasLumens
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"D" Mag Mandrel... Image heavy

Well, it's been awhile since I bored folks with some shop images so here goes. I needed a mandrel for machining "D" size Maglite heads and as I started to make it I thought it would be fun (for me anyway) to document the last steps. ... Tongue Out

 

Here the rascal is in the lathe... turned to size on both ends and ready to thread.... This was turned to size to fit the major diameter of the internal head threads on the D mag heads. If you look really close.... there are 4 diameters turned on this piece.

Mandrel On Lathe

The shadows make this image a little deceiving. If you look at the thread gauge, you think the threads are cut... look at the bottom... This is only a .003" deep "Scratch" cut just to make sure all is good with settings before getting serious. All good.

Checking Thread Count

A few minutes later the threads are rough cut and ready to check for a fit. Cutting threads to match threads that someone else cut can be fun.

Cut!

 

The head screws on ..... even with just the rough cutting done. These would /could work as they are...but no, they don't "Glide" together at this point as they should.

It Fits

 

Being a mandrel to hold the head for further machining, everything has to fit super close.... it did. (Got Lucky)

All the Way

 

Again, because it is a mandrel, it's nice to have it lock up against something to make sure all will turn true. Looking in the front, this will do the job.

  Front Side

A very light polishing at about 500 RPM makes everything glide together even without any lube. SO...when lube is added the threads are super SMEUTHE Feeling.  .... SMEUTHE.... A Texas Lumens shop term for slicker than a yeller cat!

Polished

 

Done!

All together!

This is all it takes... be SURE and grab the right number and the right lever!! ...Or is it that left one... What number was that??? What the heck is that red thing?

Lever

Thanks for letting me play. I know, it's a flashlight forum.... well there IS that D mag head in here somewhere!!!

Dan

 

 

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Fritz t. Cat
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Thanks. I haven’t seen a lath in a long time.

Flashlight designers should look at lighthouses and pottery.
这些谁设计的手电筒应该看灯塔,以及在陶器。

MRsDNF
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Thanks Mr TexasLumens Dan. One can never get sick of any sort of pictures. Its about time you posted these. Don’t leave it so long next time. About getting lucky with your thread, I don’t believe a minute of it. Smile Wink
PS, I need to borrow the mandrel. Can you please email it to me for a couple of days use. Thanks.

 

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

                      "My man mousehole needs one too"

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DB Custom
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I love pictures at the lathe of the progress being made, really cool to see. And of course, we’ll want to see what you are now going to do with the Mag Head. Wink

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Beautiful!
I always love those metal working pictures. Smile
And now I’m excited what heads you are planning to build. ^^

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MRsDNF wrote:
Thanks Mr TexasLumens Dan. One can never get sick of any sort of pictures. Its about time you posted these. Don't leave it so long next time. About getting lucky with your thread, I don't believe a minute of it. Smile Wink PS, I need to borrow the mandrel. Can you please email it to me for a couple of days use. Thanks.

Ha! I'll have to fax it to you... it will clog up my e-mail! Tongue Out You know at some point we will most likely be able to do things like that. I guess if you had a printer we could do it now!! .... See you always make my head work!!!!

Thanks! Dan.

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DBCstm wrote:
I love pictures at the lathe of the progress being made, really cool to see. And of course, we'll want to see what you are now going to do with the Mag Head. ;)

 

Thanks Dale.... I'll post some images. I'll scratch something into it! Tongue Out

Dan

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Agreed, I enjoy lathe/mill/etc pictures as much as the build pictures. So, keep them coming. Smile

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Not busting your balls, your machine work looks very good but by the look of the threads in the picture your compound was set to the wrong angle.  It should be at 29 or 30 degrees from perpendicular to the work.  

The threads in your pic look like   |\|\| instead of /\/\/\/\

Yours looks to be set to 30 degrees from parallel from the work.  This is very common since the protractor scale on lathes are not standardized.  Some read the angle from perpendicular.  Some read the angle from parallel.

Mine reads from parallel, so I have to set it to 60 degrees instead of 30 when I cut single point threads.

mrpete222 on Youtube is an excellent resource.  He talks about setting the compound at about 4:30 into the video.

https://www.youtube.com/watch?v=9y0MmvscBzg#t=271

Here is a Mag heat sink I made that screws into the head.

Mag Heat Sink

 

Cheers,


Buck

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Love it. I find so dramatic to see such industrial machinery works. Big Smile

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Bucket wrote:

Not busting your balls, your machine work looks very good but by the look of the threads in the picture your compound was set to the wrong angle.  It should be at 29 or 30 degrees from perpendicular to the work.  

The threads in your pic look like   |\|\| instead of /\/\/\/\

Yours looks to be set to 30 degrees from parallel from the work.  This is very common since the protractor scale on lathes are not standardized.  Some read the angle from perpendicular.  Some read the angle from parallel.

Mine reads from parallel, so I have to set it to 60 degrees instead of 30 when I cut single point threads.

mrpete222 on Youtube is an excellent resource.  He talks about setting the compound at about 4:30 into the video.

https://www.youtube.com/watch?v=9y0MmvscBzg#t=271

Here is a Mag heat sink I made that screws into the head.

Mag Heat Sink

 

Cheers,


Buck

I thought the same thing, I figured it was just the picture

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Looks great! Keep up the good work. Wink

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Bucket wrote:

Not busting your balls, your machine work looks very good but by the look of the threads in the picture your compound was set to the wrong angle.  It should be at 29 or 30 degrees from perpendicular to the work.  

The threads in your pic look like   |\|\| instead of /\/\/\/\

Yours looks to be set to 30 degrees from parallel from the work.  This is very common since the protractor scale on lathes are not standardized.  Some read the angle from perpendicular.  Some read the angle from parallel.

Mine reads from parallel, so I have to set it to 60 degrees instead of 30 when I cut single point threads.

mrpete222 on Youtube is an excellent resource.  He talks about setting the compound at about 4:30 into the video.

https://www.youtube.com/watch?v=9y0MmvscBzg#t=271

Here is a Mag heat sink I made that screws into the head.

Mag Heat Sink

 

Cheers,


Buck

Thanks for the note... it is the image, we run 29 degrees perpendicular to the work.  You are correct though, this is a common mistake and it does depend on the machine.  Thanks Again. Dan.

 

 

 

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I saw that as well but didn’t understand any of the degree lingo as I don’t do threads. But when I saw it, I looked at it closer and saw the angle of the picture, the angle of the light, and realized that the forward pitch of the thread was on the shaded side and the camera was centered on the face of the chuck itself, so the optical illusion came into play that the threads pitch was off. A closer inspection shows the typical inverted V shape.

Gimme more!!! Smile

I hereby officially apply for a handmade HD2010 with exacting fit and finish made in Titanium grade 23. Smile (T6061 would work but I AM a Ti freak Wink ) With a caveat. I ask that it be a production in miniature, utilizing an 14500 cell. This cell is a good down scale of the 26650. Can do? Smile

Copper pill, of course! Silly

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DBCstm wrote:
I saw that as well but didn't understand any of the degree lingo as I don't do threads. But when I saw it, I looked at it closer and saw the angle of the picture, the angle of the light, and realized that the forward pitch of the thread was on the shaded side and the camera was centered on the face of the chuck itself, so the optical illusion came into play that the threads pitch was off. A closer inspection shows the typical inverted V shape. Gimme more!!! Smile I hereby officially apply for a handmade HD2010 with exacting fit and finish made in Titanium grade 23. Smile (T6061 would work but I AM a Ti freak Wink ) With a caveat. I ask that it be a production in miniature, utilizing an 14500 cell. This cell is a good down scale of the 26650. Can do? Smile Copper pill, of course! :P

That would be a neat looking little light scaled down to a 14500 size. But Ti 23!!!  Yikes! I just felt my tooling budget rip my wallet right out of the o'le pocket!! I might play with that scaling though... I like lights with the larger head like that HD2010. Hmmm... you're doing it to me again aren't ya!  Wink   Dan.

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7075 will work. Doesn’t have to be oxygen free 6Al4V. Besides, the piece of that I had in 1” bar is now the light in my avatar and hanging around my neck. Smile

You get serious about scaling that one down and I want a shot at it, ok? Wink

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DBCstm wrote:
7075 will work. Doesn't have to be oxygen free 6Al4V. Besides, the piece of that I had in 1" bar is now the light in my avatar and hanging around my neck. Smile You get serious about scaling that one down and I want a shot at it, ok? ;)

Dale, I'll play with it and since you are the one that gave me the headache....errr... had the thought of doing that, Tongue Out you get the first shot. I might do one in Ti-4, I don't mind working that too bad. I'm behind at the present but I am catching up slowly...of course, that's what I thought six months ago!!     Thanks for the thought!!

Dan

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Encouragement, you’ll get there…

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What if you machined the reflector as an integral part of the head? The pill could deliver the emitter into the reflector from behind, with the battery tube threading in right behind it. Just because it’s Externally the same, doesn’t mean it has to be internally the same as well. Then the head/reflector would be one solid piece, adding to the heat sinking effect. For this reason alone, it should be made from at least 6061 if not 7075.

I have found a way to polish the aluminum such that it is a mirror, with virtually no markation. Now wouldn’t THAT be cool

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Speaking of trying to catch up, there is always something else pops up to interrupt. There is a certain member out there has given up on me. :_(

 

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.

 

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Here’s a better example, with different lights for size. And more what if’s…What if? You made it out of solid copper? Smile

Who gave up on ya Steve? Flat Stare

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I cant embarrass myself needless to say progress has been made today.

I’m still waiting on this mandrel to turn up. I hooked the fax back up especially and nothing has come through yet. Glad to know I’m not the only unreliable thing around here. |(

 

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.

 

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i still think an m3 head with a 14500 body would be mint..... 

just need to match the dimensions  on the head and tail of the body. last i checked, it would be like $60 for the battery tube to match solar force dimensions  

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Churn em out and we’ll buy em! Smile

The Scaled down HD2010 could even be made smaller for a 10440 as far as I’m concerned, now wouldn’t that be neat. Smile

So there ya go guys, a challenge. 3 of ya yappin and no lathework showing up! Dan, Nick, Steve, spin em up and lets see what ya got! Smile

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DBCstm wrote:
Encouragement, you'll get there... !{width:25%}http://farm8.staticflickr.com/7414/10751003806_7b584d022b_b.jpg![/quote]

 

Wow... that's one ugly red light!! Tongue Out  At least it hasn't melted!

Dan.

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DBCstm wrote:
What if you machined the reflector as an integral part of the head? The pill could deliver the emitter into the reflector from behind, with the battery tube threading in right behind it. Just because it's Externally the same, doesn't mean it has to be internally the same as well. Then the head/reflector would be one solid piece, adding to the heat sinking effect. For this reason alone, it should be made from at least 6061 if not 7075. I have found a way to polish the aluminum such that it is a mirror, with virtually no markation. Now wouldn't THAT be cool!?!

Whew! I'm sending you my lathe! I wouldn't want to do the reflector as part of the head.... but I do make a lot of lights that the pill pocket, head and short portion of the body are one piece. Then, the tube screws onto that. This can make it nice for changing battery sizes on the same light. That's all probably clear as mud after I re-read it.... an image is in order, I'll scrounge one up. Making that reflector part of the head means of course that you have to shape it into that head... working in a hole!!  It can sure be done but would... for me anyway, take awhile.... Steve did something like this I think.

I make almost all the aluminum parts in 7075. I use 6061 sometimes for internal parts like lock rings & etc... but the 7075 T61 or T65 seems to hold a finish better after blasting. It certainly holds a high polish better and for much longer than the 6061.

 

Dan.

 

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MRsDNF wrote:
I cant embarrass myself needless to say progress has been made today. I'm still waiting on this mandrel to turn up. I hooked the fax back up especially and nothing has come through yet. Glad to know I'm not the only unreliable thing around here. |(

I tried faxing you my mandrel.... now I have this big bubble in the fax machine cord! I knew I should have used OIL.... OIL needs to be on everything!! .... Make that reflector in a head for Dale!!  That will get your mind off my mandrel! Ha! Wink

Dan.

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DBCstm wrote:
Churn em out and we'll buy em! Smile The Scaled down HD2010 could even be made smaller for a 10440 as far as I'm concerned, now wouldn't that be neat. Smile So there ya go guys, a challenge. 3 of ya yappin and no lathework showing up! Dan, Nick, Steve, spin em up and lets see what ya got! :)

Pack your stuff and come on up!! Tongue Out  Odd you came up with all this. A few months... a year...??? or so ago, I was in a supply store and a guy was fumbling in his pocket and while doing so he took out a tiny little cheap made plastic flashlight and set it on the counter. Naturally, I HAD to pick it up....just had to!  What caught my eye was the proportions and scale of the light. It is a little single AA  but looks like it is a scaled down huge light.  I have it on my other desk... he gave it to me. Ugly colored little rascal but great lines and scaling.  Somewhere in China all this already exists most likely...  But, in a high end, quality light.... these might be a good piece of merchandise.  TIME.... I need more TIME.... going to the shop!    Dan.

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Can I blame it on my Aunt? When I was a kid my mom’s sister was always coming up with miniscule precision made items. At around 8 or 9 she bought me a working model of the Wankel engine, the plastic for the block and heads was all cast in clear and we put it together…well, together. It had small light bulbs for the spark plugs and you could see the firing process as the triangular piston worked it’s way around and the plugs fired under the compression stroke. My Mom’s Grandparents migrated here from Germany, and my Aunt is really into the precision German made parts. I guess I inherited that from her as I too absolutely love something delicately small but made with precision. Completely separate from that, at around the same age an older cousin gave me a copy of the Old Testament, in a version about 1” long on the long side!! Full copy of the Bible, just tiny. Thick, as you might could imagine, but readable…helped to have a magnifying glass but wasn’t necessary for very young eyes.

I absolutely adore my Texas Poker Ti Neck-light from Photon Fanatic! I designed it to look like a Leupold scope, Fred fine tuned the design and created a Masterpiece. 5 separate pieces with 8 different areas of .5mm threading, it’s just superbly done. I had originially wanted a miniature of a MagLite, but he wouldn’t copy the design.

I spent many an hour looking over a friends shoulder while he machined parts on his monster lathe at the gun shop he owned and operated. His lathe was easily capable of making rifle barrels, had a very long range of throw, must’ve been some 7’ of travel on that beast, if I recall correctly it was a 14” jaw/chuck. His end mill was also humongous, standing almost 8’ tall with a full reciprocating head for just about any conceivable angle, although it was somewhat of a bear to make those adjustments as the head was so large. These 2 machines were so massive, he poured the slab for his shop and built all but one wall, then used a fork lift to put the machinery in place, built the wall in and put the roof on the shop after they big machines were set. The mill was over 10,000 lbs and it wasn’t easy for him to find a forklift for rent that would lift it!

I was into competition hand gun shooting back then, and he ported my Ruger SP-101 snub-nosed .357 Magnum to help control recoil. That mill was outstanding! He later ported the barrel of my Glock 23 in .40 S&W, cutting a window out of the top of the slide to coincide with the milled portals in the barrel. Very fast repeat shots in competition! Loved it! A few months afterwards, Glock themselves was doing the exact same thing with their competition models!! I had also bought a 5/8” diameter rat tailed file for the single purpose of cutting finger grooves into the front of the Glock’s grip, they later incorporated those into the design as well, completely without any communications….I/we had no idea what Glock was planning, they of course had no idea I’d done the same to mine. Sometimes, a good idea is just a good idea. Smile

Since then, I’ve always been somewhat jealous of the folks with the equipment to manufacture just about anything their imagination could come up with. I didn’t know, back in the early 90’s, that the time spent in that gun shop would forever change how I looked at making parts.

A well made miniature HD2010 would be simply awesome, and don’t I wish I could stand over your shoulder and watch you make it… it would have to be polished, of course! Silly

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An attempt, got sidetracked and missed…

This was done with the piece being turned by my cordless drill, cut by my 21 year old Sears rotary tool. On the glass top of the garden table on the back porch. Smile

Got so caught up in keeping the cutting tool concentric to the emitter opening, I cut the wrong pitch on the reflector walls. Made a bowl of it, which of course would work fine for an incan but not so much for an LED. Fun, holding the drill down with the left elbow, left hand helping stabilize the rotary tool, glasses off face right in front of the spinning parts (zip tie holding the drills trigger for a nice slow rotation) and my 6 year old would suddenly appear, loud, “Hey Dad! Can I have something to eat?” The kid is always starving. lol minutes after leaving the table, he’s planning his next food attack. I wanted to scream when he did that, you just can’t afford to be startled when you’re in the finishing stages of hours of work. Eeeeeek!

The point being, if I can do this with a drill and a dremel, you’ve got no excuses!

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@ TexasLumens - Yes I gave up, but it wasn't you. After years in Manufacturing and years of dealing with tool shops, I realize that anything that is quoted will take twice as long as it's quoted for and then it probably won't fit the first time unless it was done off a CAD file to begin with...Wink

@ DBCstm - Polishing is actually easier your way, than it is with a lathe. That's what buffers are made for and it's really not as shiny as it seems. It would still need to be plated, to be the most efficient. It's the best finish for any metal reflector. Polish first, then plate it.

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