Convoy S2 Triple Nichia 219B Build - Complete!!

Flashlight Modding and DIY Parts
1

Well, I know this build will be pretty basic for some. However it was the next step in modding for me and I’m pretty excited about it as it went to plan perfectly!!

So, it started out when Intl-Outdoor announced on here that they had started stocking the Nichia 219B. I had always been fascinated by the Nichia’s as people really bang on about how nice their tint is, but I was yet to use one myself. Someone in the thread had mentioned the possibility of Hank doing a triple Nichia on a Noctigon which then got me quite excited as I have never used a triple emitter in a build before. Anyway long story short, I purchased the Triple Nichia, a 3.04A Qlite, some extra 380mA 7135 chips, three different Carclo optics and decided to try it all in a Convoy S2 as I already had one and really liked the host.

This would need some heatsinking as well as some extra length to make up the space which the reflector was no longer occupying. I purchased some 19mm copper bar, took some measurements, did a rough sketch and took it to a friend who had a machine shop. A little while later and I had this…

I then took the piece of copper and soldered it to the standard brass pill which the S2 comes with…

Followed by some polishing of the surface using some 1200, 2000, 3000 grit sand paper followed by some Autosol (I know it isn’t perfect :frowning: )

To power it I was going to need more than the normal 3A of output that the Qlite offered. So I stacked 4 380mA chips to it. I had done this before but to make it a little easier this time I used my dremel and a cut off wheel and chopped off the centre pin on all the chips which helped to stop the solder jumping across which can be quite annoying. At this time I also added some Chemtools No. 2 braid to the spring and soldered the 4th star giving me moonlight, low, medium and high modes…

I then soldered the pads on the Triple Noctigon board so that it would be operating in parallel…

Then fitted the star and the driver into the pill using some Arctic Silver 5 thermal paste…

Finally I braided the switch spring, fitted the pill into the host along with a Carclo 10507 (narrow beam) optic and changed the tailcap rubber boot to a GITD blue one…

And last but certainly not least. Anyone that has stacked chips will know how much of a relief it is to see this after everything has been assembled and operated…

And there you have it… My Triple Nichia 219B Convoy S2 build. Needless to say I am stoked with the outcome. It came together perfectly and the beam is simply awesome. I haven’t got any beam shots yet as it is the middle of the afternoon. But tomorrow night I should be able to get something.

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Does anyone sells fabricated copper spacer for S2?

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Yeah, I’d like a few please.

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Hey! I’m really loving this build. Do you think you would be willing to sell or make another coppers block thingy ? I want to replicate it but can only obtain the parts I can buy. Don’t have access to a lathe.

Cheers !

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Nice mod LSX. You dont want to leave this on in your pocket.

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Cheers guys! And you’re right MRsDNF even with that chunk of copper it warms up nicely on high! haha

Unfortunately I don’t think I will be able to sell any of the copper spacers we made for this. Copper isn’t the nicest material to machine and the mate that helped me is usually flat out, I organised to do it this weekend about a month ago! Sorry guys! If you go to any machine shop though and supply some copper to them I am sure they will do it without a problem. I just went to a metal supplier that I found online and got about 100mm of 3/4” copper bar for like $7.

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+1

I want to do this. Nice work LSX!

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Could you get a sketch of the piece please?

And if we get an s2 and get that piece machined will it be a close enough fit to end up like your build ?

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+1

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Give us a radius and height please, I just realised that my contractors have machine shops. Now for the copper round stock.

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All you guys wanting Copper spacers, it’s really easy and will cost you about $20 MAYBE $30 max.

Step one- buy aluminum spacer from MtnE and piece of copper (at least 2”) from onlinemetals.com

[Once delivered] step two-buy case of beer

Step three- head to ANY local machine shop with metal, beer and the spacer you bought so the guys there don’t have to do any figurin, just make an exact copy of the part you supply. They’ll charge you <$10 if that.

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So it is 3/4” (19mm) copper bar which was a standard size at the metal supplier I went to. All we did was turn down the end to I think 15.2mm I am not 100% on this as we just turned it down until it was a nice fit in the centering ring on the S2 pill and about 2mm up the length. Overall length from face to face was 15mm on the dot.

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Sorry I don’t have AutoCAD on this computer, only MS Paint! haha

You need to check the 15.2mm measurement!!! We just turned it down until it fit nicely into the ring on the S2 pill…

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It’s a great design even for MS Paint. Thank you.

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Most appreciated LSX. Gonna go buy a lathe and learn how to operate it.

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haha now that’s dedication!

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I love that mod, thanks for sharing! In my area is not feasible to get the copper spacer at a reasonable price, somebody knows some host a spacer is not necessary to put triple LED board? or organize a group buy to a Chinese manufacturer :bigsmile:

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You drilled an hole in the pill right? So it will not work for people who do not have access to drill.

I actually thought of getting local machine shop to fabricate copper C8 pill in the past. However, it might be a cheaper option to order from fellow BLFers instead. Copper rods are very expensive in my country.

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Yeh I drilled a hole through the pill. It is necessary to use the triple. I would imagine though if you get to the point of using the drill after the copper has been machined and soldered I would be surprised if drilling a single hole became an issue. We drilled it with the same lathe that we machined the copper with.

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Very nice build! I love compact triple lights.

You can get aluminum spacers here . For all practical purposes they will work as well as copper.

If you insist on copper you can make your own with hand tools like this . Not quite as pretty but works just as well. I bought a 12”, 3/4” copper rod about 2 years ago, used it to make 7 or 8 heat sinks (4 triples) and still have plenty left.