The Raven- 10440 Minimag in black - Had to fix it

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Rufusbduck
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The Raven- 10440 Minimag in black - Had to fix it

Or maybe a blackbird with delusions of grandure.

Thin fins

Lots o’ new stuff

A bit of a setback

Body assembled

Had to fix it

First sketch.

Some parts.

There are some corrections to be made but since there will be so many pieces going into this head I figured I’d better map it out a bit. Usually I just wing it.

****

Second effort(well third actually but the second one you get to see). I’m not at home so the bezel might be off but this is as much as I’ll need to go on.

Here we go! I started today by wrapping up the head in masking tape and pressing it into a block so I could start the bore with a step drill. It does a nice job self centering but can’t drill all the way to depth.

Then I put a dremel blade in the drill press and cut the bezel threads free while keeping the o-ring groove intact.

Success!

I set these aside for now and while I had the dremel blade installed I cut a 5/16” brass compression union in half, put one of the halves in the vise with the cap on and reamed it out from both ends again using the step drill. The inner piece was finished off with 200 grit taped to a drill bit and spun until it was the correct size. The outer piece(the compression cap), I ground the points off with the grinder then again snugged this part onto a 3/8” bolt and spun it first over a file and then over 200 grit. Lapping is not necessary for either of these. Here is how they look now with the other half of the union pieces in back and a p60 pill to the side.

Now I need to finish reaming out the head pieces. More tape, sandpaper, and spinning. I went through several layers of skin but got the bezel threads done.

But I still need to finish reaming the head so the outer brass part fits.

Time to go to sleep and grow some more skin.

Here is a pic of the head with the tools I used to finish the bore. The bit on the left was used in the dremel to keep the bottom of the bore square and the variable Dia sanding drum on the right removed the rest of the material. Took about 2hrs.

I used a dremel cut off wheel(thanks OL) in the drill press to cut the sleeve the correct length to fit into the bore.

The next thing on the list was some brazing which I haven’t done in awhile and slagged the first two parts I tried. Fortunately that union had two ends and effed up small parts are a small loss. In the end I got the brass male threads brazed to a brass plate that is the last fin and a small bit of copper brazed into a section of 5/16” copper tubing shown here prior to the first attempt.

The next pic is of the rough fins with the two part brass bit mentioned above at bottom left. I’m not sure yet if I’ll use these or go with a slightly thicker guage. I depends on how they stack up.

One thing I’d been having trouble doing is widening the center hole on smaller discs. If I put them in the vise with enough sticking out for the step drill to work they would either get mangled or squirm out IC the vise. Solution: sandwich it between two pre-drilled pieces, clamp one end in the vise and use my sheet metal vise grips on the other. With the pre-drilled hole it’s easy to center the disc. It stays flat and secure, and the step drill clears both clamps. Basically a miniature version of how I cut the rough discs from the sheet stock.

Lastly, I cut the wire spacers that go between the fins. This is .6 mm wire scavanged from multi conductor sprinkler control cable. After stopping the insulation, for each section of spacers I wrap the wire around tubing one size smaller so that it stays tight when I slip it around the correct piece and cut it.

That’s all for now. Soldering this thing is going to be a pain and I need to think on it so the next thing will be stacking the 10.5mm driver(now 10.2mm), sleeving the chips, and making the contact plate.

Here we have the 10.5 mm driver next to an mt-g2 and a double and triple stack of chips. I’ll be adding the triple stack here.

After sticking the stack in place with a dab of JB weld and allowing it to cure I soldered a short solid wire to pick up the led – pins and a longer one that goes through the pcb for led+. Some Teflon wire case is slipped over the solid wire and will be slid down tight to the pcb.

A big plus for the newer design driver board is through holes for both led+ and led- located at opposite ends of the board just like the mcpcb’s . This makes it possible to orient the chip stack either toward the battery or toward the led depending on where you have room. They also make a more secure connection for the wires. The board in this build is one of the beta boards without these features.

Next I’ll add the pwm wire and pot this stack in a nylon sleeve filled with Fujik. After that cures, I’ll add a tinned copper contact plate. An led-wire will make it ready to install.

A little side step. I brazed two more pieces and fitted them to the inner most copper part to which I added some more copper bits. On the left is the first brass fin with its threaded sleeve, next is the copper sleeve that will have the copper fins stacked on it, and then the inner post that gets the led on top. There are 4 pieces of brass in the first, two pieces of copper in the second, and 4 pieces of copper in the third.

And here’s how they fit together.

And,

p.

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

Scott

Edited by: Rufusbduck on 05/03/2014 - 02:34
MRsDNF
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I will not understand anything from now on but I definitely understand what you have drawn above. For once you are speaking my lingo. Thanks.

 

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.

 

jacktheclipper
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Once upon a midnight dreary, while I pondered, weak and weary,
Over many a quaint and curious volume of forgotten lore—
While I nodded, nearly napping, suddenly there came a tapping,
As of some one gently rapping, rapping at my chamber door—
"'Tis some visitor," I muttered, "tapping at my chamber door—
               Only this and nothing more."

Ah, distinctly I remember it was in the bleak December;
And each separate dying ember wrought its ghost upon the floor.
Eagerly I wished the morrow;—vainly I had sought to borrow
From my books surcease of sorrow—sorrow for the lost Lenore—
For the rare and radiant maiden whom the angels name Lenore—
               Nameless here for evermore.

And the silken, sad, uncertain rustling of each purple curtain
Thrilled me—filled me with fantastic terrors never felt before;
So that now, to still the beating of my heart, I stood repeating,
"'Tis some visitor entreating entrance at my chamber door—
Some late visitor entreating entrance at my chamber door;—
               This it is and nothing more."

Presently my soul grew stronger; hesitating then no longer,
"Sir," said I, "or Madam, truly your forgiveness I implore;
But the fact is I was napping, and so gently you came rapping,
And so faintly you came tapping, tapping at my chamber door,
That I scarce was sure I heard you"—here I opened wide the door;—
               Darkness there and nothing more.

Deep into that darkness peering, long I stood there wondering, fearing,
Doubting, dreaming dreams no mortal ever dared to dream before;
But the silence was unbroken, and the stillness gave no token,
And the only word there spoken was the whispered word, "Lenore?"
This I whispered, and an echo murmured back the word, "Lenore!"—
               Merely this and nothing more.

Back into the chamber turning, all my soul within me burning,
Soon again I heard a tapping somewhat louder than before.
"Surely," said I, "surely that is something at my window lattice;
Let me see, then, what thereat is, and this mystery explore—
Let my heart be still a moment and this mystery explore;—
               'Tis the wind and nothing more!"

Open here I flung the shutter, when, with many a flirt and flutter,
In there stepped a stately Raven of the saintly days of yore;
Not the least obeisance made he; not a minute stopped or stayed he;
But, with mien of lord or lady, perched above my chamber door—
Perched upon a bust of Pallas just above my chamber door—
                Perched, and sat, and nothing more.

Then this ebony bird beguiling my sad fancy into smiling,
By the grave and stern decorum of the countenance it wore,
"Though thy crest be shorn and shaven, thou," I said, "art sure no craven,
Ghastly grim and ancient Raven wandering from the Nightly shore—
Tell me what thy lordly name is on the Night's Plutonian shore!"
               Quoth the Raven "Nevermore."

Much I marvelled this ungainly fowl to hear discourse so plainly,
Though its answer little meaning—little relevancy bore;
For we cannot help agreeing that no living human being
Ever yet was blest with seeing bird above his chamber door—
Bird or beast upon the sculptured bust above his chamber door,
               With such name as "Nevermore."

But the Raven, sitting lonely on the placid bust, spoke only
That one word, as if his soul in that one word he did outpour.
Nothing further then he uttered—not a feather then he fluttered—
Till I scarcely more than muttered "Other friends have flown before—
On the morrow he will leave me, as my hopes have flown before."
               Then the bird said "Nevermore."

Startled at the stillness broken by reply so aptly spoken,
"Doubtless," said I, "what it utters is its only stock and store
Caught from some unhappy master whom unmerciful Disaster
Followed fast and followed faster till his songs one burden bore—
Till the dirges of his Hope that melancholy burden bore
               Of 'Never—nevermore.'"

But the Raven still beguiling my sad fancy into smiling,
Straight I wheeled a cushioned seat in front of bird, and bust and door;
Then, upon the velvet sinking, I betook myself to linking
Fancy unto fancy, thinking what this ominous bird of yore—
What this grim, ungainly, ghastly, gaunt and ominous bird of yore
               Meant in croaking "Nevermore."

This I sat engaged in guessing, but no syllable expressing
To the fowl whose fiery eyes now burned into my bosom's core;
This and more I sat divining, with my head at ease reclining
On the cushion's velvet lining that the lamp-light gloated o'er,
But whose velvet violet lining with the lamp-light gloating o'er,
               She shall press, ah, nevermore!

Then, methought, the air grew denser, perfumed from an unseen censer
Swung by Seraphim whose foot-falls tinkled on the tufted floor.
"Wretch," I cried, "thy God hath lent thee—by these angels he hath sent thee
Respite—respite and nepenthe, from thy memories of Lenore;
Quaff, oh quaff this kind nepenthe and forget this lost Lenore!"
               Quoth the Raven "Nevermore."

"Prophet!" said I, "thing of evil!—prophet still, if bird or devil!—
Whether Tempter sent, or whether tempest tossed thee here ashore,
Desolate yet all undaunted, on this desert land enchanted—
On this home by Horror haunted—tell me truly, I implore—
Is there—is there balm in Gilead?—tell me—tell me, I implore!"
               Quoth the Raven "Nevermore."

"Prophet!" said I, "thing of evil—prophet still, if bird or devil!
By that Heaven that bends above us—by that God we both adore—
Tell this soul with sorrow laden if, within the distant Aidenn,
It shall clasp a sainted maiden whom the angels name Lenore—
Clasp a rare and radiant maiden whom the angels name Lenore."
                Quoth the Raven "Nevermore."

"Be that word our sign in parting, bird or fiend!" I shrieked, upstarting—
"Get thee back into the tempest and the Night's Plutonian shore!
Leave no black plume as a token of that lie thy soul hath spoken!
Leave my loneliness unbroken!—quit the bust above my door!
Take thy beak from out my heart, and take thy form from off my door!"
               Quoth the Raven "Nevermore."

And the Raven, never flitting, still is sitting, still is sitting
On the pallid bust of Pallas just above my chamber door;
And his eyes have all the seeming of a demon's that is dreaming,
And the lamp-light o'er him streaming throws his shadow on the floor;
And my soul from out that shadow that lies floating on the floor
               Shall be lifted—nevermore!
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…Always watching! (favorite lines from Monster’s Inc)

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I get it, I think. Wink

and I'm looking forward to it.

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

 

LSX
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Wow, I didn’t realise the amount of work that will be going into this! Unreal! I’m humbled that I will be receiving such a generous gift!

I have already ordered some Efest 10440 IMRs in anticipation.

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OOOH!!!

I see, the copper to make rings, the washers to make fins!

Awesome!

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And following on from above, headaches, frustration, lots of naughty words, packets of bandaids. determination and skill to create what will ultimately be a work of art.

 

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
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This one even required a quantum leap to graph paper from bar napkins…impressive!

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The high current and associated heat pushed me to this extreme. See the op in HD2010 pills by Bucket for my other recent foray into graph paper design. For some reason a bar napkin doesn’t translate well to 3 digit accuracy on a lathe. What accurate drawing does do is let you see exactly where imagination clashes with the limitations of machine work and provides a language text that crosses continents without mistranslation. The proof is that MRsDNF understands my plan. There isn’t any lathe work on this but there were just too many tiny pieces to keep track of otherwise.

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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We’ll just assume that your highly odiferous friends helped with this plan anyway, would be horrible to leave Jack, Johnny, and the legendary Captain Morgan out of such equations as these!

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New sketch in op.

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 knew it would not last long. I’m still following thanks but making the electronic like stuff. Nup ya lost me.
Just had another look there stacked right? I couldn’t solder it together but understand it, back on track.

 

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.

 

LSX
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How do the copper/brass fins and copper rings attach ? Is a segment of the head machined away?

Intriguing…

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The Master of Miniscule invented intrigue, grab your popcorn and enjoy the ride as no one re-creates a light like the Duck. Wink

He fits all the pieces together, layers of copper pipe and brass pipe sleeved together to perfection, sandwiches the rings and fins and solders the entire thing together into a solid piece. And if it doesn’t cooperate, he disassembles it all and redoes it till it’s perfect. Cause that’s the way Scott rolls. Smile

Each part of the puzzle has it’s own genius behind it, each technique and implementation a new level of genius, like playing 3D Chess with Dr. Spock. :bigsmile:

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Wow, that is quite a design, very complex, very nice, watching! Smile

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Now that I have a design (not set in stone, that part I still wing it), I can bore the head back halfway through the threads. There are 2 1/2 full turns and I’d like to keep ~1 1/4. That gives me about 16-17mm to play in. Then I’ll cut the head just behind the o-ring land and all those extra bits fit between the cuts and into the bore. Because of some of the geometry I’ll have to braze certain parts together so that the don’t come apart or slip when I solder others. Each fin, each wire, each set of parallel lines is a separate part(by my count 24, not including the Sinkpad or driver), all in a space about the size of a p60 pill. On the first few I made a separate pill for the led and driver that was a slip fit into the rest. Because of the higher drive current on this one (1.5A on high) I wanted to try a one piece design(albeit soldered) but with more larger fins. I also wanted to retain access to the driver which is why it’s threaded into the back half of the head. The brass male threads at the driver end will be brazed to the first brass fin but the female threads there and the male bezel threads will be epoxied with JB weld. Getting sketches done and my brain wrapped around it to the point where I can see the process in my minds eye takes time and I’ve learned from unfinished projects not to start until I can do that. I can’t always do that but I much prefer it that way. Today I start cutting so check back for updates.

Scrolling through the op in edit mode is a pain, what did you all think of my use of links for updates in the last build?

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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Are you using advanced input format?

 

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.

 

Rufusbduck
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I’m using the iPhone input format. Keypad takes up 2/3 of the screen and on a long post the text doesn’t all fit in the box and I have to navigate out of the box without having the cursor move to get to the controls and input pics, links, paragraphs, etc. after a few edits in the op it’s much easier to put updates at the current end of the thread and put a link at the top of the op. Then, no matter how many posts follow the stages of the build can be tracked. Since there’s just descriptive explainations in Post 16 I might not link that or if I did just put“blah, blah, blah” in the link text box. Just for you I also edit the thread title with each new link added.

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 hate using a phone to even read threads let alone try and post with one. What you did last time from memory works fine by me. Just remember lots of pictures and waffle. 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.

 

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I know a lot of people do that, but to me it’s just nuts. I don’t have a smart phone though so that probably explains it. I can’t imagine reading this forum and looking at the pics on anything less than my 24” monitor. lol. Heck, I’ve had bride and groom try to pick their pictures out on smart phones, baffles me.

However you do it, keep it coming. And make the pictures bigger if you will, I just ordered an M1 and need to see your shot’s closer so I can copy you…

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First bump.

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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Incredible. There is no way I would have the skill to modify lights to this sort of degree!

I am still a bit lost with how it will all come together in the end, but will be following this thread closely to watch it all unfold!

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Sweet dreams and may the skin grow back. Was it burnt or cut flesh?

 

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.

 

Rufusbduck
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Quote:
Incredible. There is no way I would have the skill to modify lights to this sort of degree! I am still a bit lost with how it will all come together in the end, but will be following this thread closely to watch it all unfold!

Check out my earlier mods. I haven’t done all that many. There’s a steep learning curve. Just try it. Screw up. Learn. Get better. It’s fun.

Quote:
Sweet dreams and may the skin grow back. Was it burnt or cut flesh?

Sanded off holding the part between my fingers and spinning the sandpaper. Even calluses don’t last forever.

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 like how various parts of the build look gruesomely ugly and then it beautifies in the end. Smile When I reflowed a 20mm Noctigon with MT-G2 onto the 7/8” diameter 1” long copper heat sink for my L2m, when it was done it was all one piece and working perfectly, but the heat really made the copper ugly, not to mention some flux overflow. lol

What’s the old saying “It all comes out in the wash.”

You’re off to a great start, have fun! Smile

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Second bump.

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 hope the masking tape is hiding bare flesh and not holding fingers on. There seems to be a thumb nail missing in that picture.
I dont have any hints for you at all boring holes out in little thin pieces of fragile steel. Looking good.

 

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.

 

Rufusbduck
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Index finger is missing the end. The tape was to protect them from the thin edges of the discs should it “grab” and spin I my grip. Ugly but it worked. The last few thou on each hole had to be done by reaming with the sanding drum.

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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You are one tough cookie.

 

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.

 

Rufusbduck
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Third bump.

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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