2014 - Contest Light - 1st place prize light - DONE!! Video added and beam shots are up in Post#1

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Old-Lumens
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2014 - Contest Light - 1st place prize light - DONE!! Video added and beam shots are up in Post#1

 

I was not going to post anything till the end of the contest... Well, you had to know that would not last! I just figure there's a month gone already and not too many have started their builds, so here's a look at what the third place prize will be. It will either make you want to win third place, or it will make you want to run and hide, for fear you actually might get it as a prize.

2nd1a

This is what I started out with and as things progressed, the components also changed to suite the needs.  This is a Solarstorm SP-03. I am going to put 3xMT-G2 leds in it. I am going to use 8x18650 batteries in 2S/4P configuration. It will be fan cooled. It will not look anything like the stock light... I sure hope it works.

 

 

 

2nd1b

I put this photo in, because I did not take any of when I cut the head apart. I used a hacksaw to cut the head in two, right where the switch was. I am going to extend the head, to have room for the heat sink, fan and driver.

 

2nd1c

This is the copper heat sink that will fit under the stock led shelf.

 

2nd1d

I did not like the dimples in the led pockets, so I drilled them out.

2nd1e

and replaced them with copper discs.

2nd1f

 

 

 

 

2nd1g

I got a finned aluminum heat sink and a fan. The fan here is not the one I ended up with. This one was 50x50x10 and the one I ended up with is 40x40x20. There was not enough foom for the 50mm fan, but the 40mm actually produced more CFM.

 

2nd2a

Here is the cut out heat sink and the fan is mounted on a copper plate. There is also a thermostat down in there, so that the fan only runs when the temp of the heat sink gets to 60C.

 

 

 

2nd2b

I started out using copper, to make the extension for the head. I softened it and made the bends on the table, as shown below.

2nd2c

The problem was that the piece was not tall enough, so I ended up going to brass sheet, which you will see later, but this was the method for bending the brass too.

2nd2d

 

 

 

 

2nd2e

I needed two bodies to hold the 8 batteries, so I used an old SRK body and put it together with the stock body. I had to cut down both of them, so that the overall length would be right for two batteries in series.

2nd2f

I did the human lathe routine, to fit the two bodies together and used some JB Weld to make sure they hold. I made the SRK body look like the stock SP-03 body by removing those ribs on it.

 

2nd2f

The bodies lined up well and I think it will work.

 

 

 

 

2nd3a

Ok, remember I said I ended up using brass for the extension. Well, here you can see what it looked like before cleaning it up. I also made a brass sleeve on the bodies to cover up the mess there.

 

 

 

2nd3b

I removed the components from the stock driver and I will use it for a contact plate.

 

2nd3c

The board in these two photos is one that was designed by Mattaus, for this build. Originally, I was going to do 9 amps per led and he designed this board for 3 legs with 9 amps per leg. I ended up backing off and going with 6 amps per leg after being cautioned on my folly, by comfychair. He was right, even with 2S/4P, there isn't a cell out there that would hold 27 amps for more than a few seconds, because of the low amp hour rating on them. They just would not last at all and when the voltage dropped a little, it would just go dim. So, I went with 16 chips per leg, for about 6 amps per led. It still won't last long, but it will be better than a 30 second wonder, (I hope).

2nd3d

 

 

 

 

 

2nd3e

Since I cut apart the stock switch hole, I decided to put the momentary switch in the handle. Here's a couple shots of that.

2nd3f

2nd3g

2nd3h

 

 

 

 

 

2nd4a

Here's a couple photos of the brass extension in place. I've cleaned it up a little and I ended up polishing with steel wool and clear coating it. The screws are stainless steel.

2nd4b

 

 

 

 

2nd4c

I ended up painting the body. There was no way I could clean it up well enough to leave it, so I used the same rough finish paint that I have done many times. I like the copper showing through.

 

 

 

2nd4d

I had to drill out the led holes in the reflector for the MT-G2 leds to fit. I used the drill press and I ended up drilling from the bottom, instead of from the top as shown. I just couldn't risk ruining the reflector by doing it this way.

2nd4e

 

 

 

2nd4f

I coated the copper heat sink before putting it in the head.

2nd4g

Then I wired up the leds and stuck them down in. I only used thermal grease here, since there is a bolt going all the way through the center and everything gets tightened down when the bolt tightens the reflector down into the head.

2nd4h

Finished product. One head ready for the next steps.

 

 

2nd4i

Luckily, I had a metric bolt laying around, but I had to file the head round, since it was a hex head and I cut a slot in it, so I could use a screwdriver to tighten it down.

 

 

2nd5a

The aluminum heat sink is glued down and the fan is in place.

 

 

2nd5b

The brass extension is in place too.

 

2nd5c

 The top plate is copper and it is silicone in place. Hopefully it will help to seal a bit, so any water won't run into the driver area, but this is Not a water resistant light. It would be best to not expose it to rain.

---------------------------------------------------------------------------------------------------------

I managed to get the slave board in and it's wired, but now I don't have a good master lying around, so I need to wait a few more days. Sorry.

sp4b

I put a copper disc over the bottom side of the board, glued to the 7135 chips with AA. It might help a little with heat... or not.

sp4a

I will put another disc or rectangle on top of the board, after everything is wired up and tested.

---------------------------------------------------------------------------------------------------------------------------

 Last time, it looked like it was mostly done. Well, the driver came in from RMM and I hooked it up. It almost worked! Two leds worked as advertised and the driver cycled with the switch, but the third one just came on high and wouldn't cycle... Shorted to ground. I tore everything apart and found the reflector was pressing on the led substrate, causing the short.

Sooo... Time to make changes.

sp31a

I put kapton tape on the reflector. See, most of these multi reflectors have metal between the led holes and that acts as a stopper. This one does not. The led holes rest right on the substrate. When it was an XM-L, it rested on the centering ring, but with the MT-G2, it rests on the substrate.

 

sp31a

I also added three stoppers, so that the reflector will not compress too hard on the substrates.

 

sp31c

The third thing I did was to switch to silicon coated wires. The Teflon ones were just too stiff to work well.

Now, I can reassemble everything and see how it goes this time.

-------------------------------------------------------------------------------------------------

Finished!

sp4aa

I don't have 8 batteries for it, so I am testing with 2S/2P Panasonics

sp4dd

And it works this time!

 

 

sp4bb

Final wiring

sp4cc

 

 

 

Shots of the finished light. It's a very strange looking light.

sp4ee

sp4ff

sp4gg

As I said, I don't have 8 matched batteries, but I did have 8 total batteries, so I tested them. I had to get it hot to make sure the fan works. The fan does work, but I wish I had used a 40C thermostat instead of a 60C. The head gets hot! Very hot! The batteries start to gim before the fan turns on, but it does turn on.

Almost a total success, but at least it does work. Guess I should be glad for that.

 

05-17-14 I am going to tear it down and use a lower temp thermostat, so the fan kicks on sooner and I need to tackle a ground issue, so it ain't over till it's over, but there's a beam shot in post #1 to tide y'all over.

 

Listen to the light, Tongue Out

Beam shots will be done tonight (6/4/14)

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

 

Edited by: Old-Lumens on 06/21/2015 - 10:47
Old-Lumens
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I have a Thrunite T10 with a Nichia 219 in it and a HD2010 that does 65k lux at one meter, for reference shots. I liked the HD2010 and I have used it quite a bit. I thought it was a bright light, well, not any more.

 

sbs1

T10

 

 

sbs2

HD2010

 

 

sbs3

OMG

 

 

 

sbs4

T10

 

 

sbs5

HD2010

 

 

sbs6

It literally hurts my eyes

 

 

 

sbs1a

HD2010

 

 

sbs1b

Wall of light

 

 

 

sbs1c

HD2010, I used to be impressed

 

 

sbs1d

Nothing will ever be satisfactory after this light.

 The camera doesn't even do it justice. In real life, that blue haze is hardly even noticeable and the light is much brighter in person.

 

OK, that's it. I still did not use a matched set of batteries, but I ordered a set of eight of the 25R, to go with this light. Yep, it's now officially the brightest and most expensive light I have ever done.

Yep, it's now 1st prize in the contest... Hey, it is my contest ya know...

 

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

 

unknown00101
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Sometimes I’m glad I have a really bad sleep schedule and get to see some crazy OL build before I finally hit the hay. Smile

I think this is the most custom build I’ve seen to date. Incredible. Can’t wait to see the finished product.

DBSAR
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This is.. WOW. Smile

That Canadian flashlight guy & Lantern Guru -Den / DBSARlight

DayLighter
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wow.. good thing I’m still up.. now I can go to sleep and dream I’m a lighting thief holding this flashlight Big Smile

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

cainn
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OK, Old-Lumens has finally gone off the deep end, and I don’t think there’s any coming back.

The good news is that some of you are going to reap the rewards of this most fortunate development Wink

FlashPilot
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Im completely blow away by this monstrosity! I knew you had something in the works with active cooling… but man, you’ve gone way over the top! Friggen awesome! :bigsmile:

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HOLY!!!!!

WHOAH! That thing is going to pump out the light!

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Certainly not all your designs appeal to me, and find the amounts of massive copper in the builds usually overdone, but this monster has what it needs inside to make it work (8000 OTF lumens? 6A runs the MT-G2 at 75% of max, which is my personal sweet-spot for mods), and the looks are on its way to look perfectly scary and awesome!!

MRsDNF
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Thanks OL in advance. I was never in the comp to win it but to come third. You have my mailing address and thanks for putting us all to shame. CryLaughing

 

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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Wow, that is one epic light!

southland
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Holy cow, that’s awesome.

cainn
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MRsDNF wrote:
Thanks OL in advance. I was never in the comp to win it but to come third.

Hmmm, what a precarious situation. You’ve gotta make something good, but not too good. But you’ve gotta hit just the right amount of not too good. Too much not too good might drop you to 4th. Not enough not too good and you might inadvertently hit second. So the question is, what is the right amount of not too good?

I don’t envy you.

(I don’t envy anyone who tries to read and understand the entirely of this post either)

Anyway, good luck!

sandalian
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Wow, that’s a monster! Flat Stare

I'm switching my BLF account into LumenZilla. Thanks!

Ejected Filament
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Awesome light Dr Frankenstein. That sucker will start fires.

cainn wrote:
MRsDNF wrote:
Thanks OL in advance. I was never in the comp to win it but to come third.

Hmmm, what a precarious situation. You’ve gotta make something good, but not too good. But you’ve gotta hit just the right amount of not too good. Too much not too good might drop you to 4th. Not enough not too good and you might inadvertently hit second. So the question is, what is the right amount of not too good?

I don’t envy you.

(I don’t envy anyone who tries to read and understand the entirely of this post either)

Anyway, good luck!


Even if he found the perfect amount of not too good, that right amount of not too good may still be too good and win first or second, if others also try to position themselves for third, making the right amount of not too good, still too good, and too much not too good perfectly not too good by not being too good compared to other peoples interpretation of not too good. Of course without hindsight, the wrong amount of not too good being the right amount of not too good is again, purely speculative.

My guess is that lights use in Victoria, NSW, Tas and SA during the summer months, would be banned due to the fire danger.

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o m g – what a build!

looking forward to the day it will be alive Big Smile

PLEASE NOTE
i do not work in "reviews, deals and codes" for the time being
maybe M4D M4X will return one day, but until then:

THANK YOU FOR YEARS OF YOUR SUPPORT AND FRIENDLY CONTACTS!

Ervin Anastasi
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hahaha nice that’s not a flashlight, that is a cannon of photons Smile

some of my actual experiments and reviews:
UF-T20 review and mod —->http://budgetlightforum.com/node/30186#node-30186
My EBRZM, over 1 million cd thrower—-> http://budgetlightforum.com/node/30274#node-30274
Ervin’s try (2nd. Annual BLF Scratch Made L

Gj
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Yikes! Cool

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I’m drooling… This is just the third place prize?!

Slewflash 

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That’s the kind of beauty & craziness I like, great work! Big Smile
I’ll be using forced air cooling because I like the concept . . . that thing actually needs it. ^^
To whoever gets this thing: I see abdominal muscle aching from all the giggling in your future! Silly

blfdemigod
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Wow, incredible! What happens if you point this at a bird in mid-air?

My collection 2 Small

Disclosure:

MRsDNF
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Graft and corruption is well and truly alive in this wonderful world we live in.Tongue Out

 

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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You guys just keep wasting your time figuring out how to make your lights just the right amount of bad. Mine will be the baddest(easier done than said) so I can focus my efforts on well timed bribery.

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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Another amazing build.

RaceR86
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Very Impressive OL. Very impressive!

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

RMM
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Wow!  To try and quote MRsDNF, "orsm!" Sealed

OldLumens (or someone else,) could you please remind us all about the details about the contest?

Mountain Electronics : batteries, Noctigon, and much more! What's new? 

18sixfifty
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That is just too Cool. Just amazing is all I can say. Smile

I’m a junky, I mod lights so I can sell lights so I can buy more light to mod so I can sell lights to buy more lights to mod.

Old-Lumens
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RMM wrote:

Wow!  To try and quote MRsDNF, "orsm!" Sealed

OldLumens (or someone else,) could you please remind us all about the details about the contest?

http://budgetlightforum.com/node/30014

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

 

onetrickpony
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OL, you succeeded in getting me to get my butt in gear about thinking about what I’m going to think about building. I did find a sheet of copper my father gave me. He told me I could use what I needed but to give back what I didn’t. That was five years ago, and I’m lucky he’s an understanding man, because I don’t think he forgets much. I’m also going to assume he has faith in my stewardship…

I will say this, the current plan is 4xAA, with what I think is a very unusual mounting location for the led, as well as a vexing problem as to where I’m going to place the switch. I think I’ve got the battery connections and layout figured out, but to be honest, I haven’t built a thing yet.

No excuses, just trying to mentally prepare for the obstacles so that they aren’t as painful in real time. Smile

scottyhazzard
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That’s third place! Must be one of the first times in the history of competition that people are hoping to get third. Darn nice looking light. I’m looking forward to see how this come together.

"Those who hammer their guns into plows will plow for those who do not."

ToyKeeper
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Wow.

I’m not really sure what else to say. Just wow.

Triple MT-G2 at 6A? 100+ watts on the most efficient emitter on the market? Active cooling on a massive heat sink? The amount of lumens coming out of that might actually be, as they say, over nine thousand. If Chloe got a hold of it, the result might look something like this:

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