Courui Big Head overhaul with XP-G2

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FmC
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Courui Big Head overhaul with XP-G2

 I know there's already a few threads going for the Courui, but I thought I'd put this up as a quick reference that addresses the issues with the stock light.

 The only components I have replaced are the stock wiring, as it's about as thick as a gnat's hair, & swapped out the MCPCB for an XP-G2 on a 32mm Noctigon. I also added a tail switch for lockout.

 I started at the rear of the light by using 22 gauge silicone wire to upgrade the springs;

 

  Then on the back of the board, removed the tiny stock wire & added an Omten switch, connected to each via by 18 gauge wire. A 13.5mm hole was also drilled in the cap to accommodate the boot;

 

 Next was the pill assembly. The pill was turned over, sanded flat, drilled & tapped for the 32mm Noctigon, which was also lapped. Screw holes were countersunk to avoid interference with the reflector base.

 I didn't bother with sanding the pill all the way down to remove the grind marks, as it's really not necessary - the copper board is doing the work here, & there's plenty of surface area where it mates to the pill top.

 

 The underside of the reflector is completely flat, & 26mm wide, which is going to make things tricky to get it sitting low;

 

 I figured the best way would be to make up some thin copper tabs, & get the wires away from the reflector. I also filed a small bevel on the base of the reflector for added clearance.

 Here's the pill assembly ready to go, with the now de-domed XP-G2. I used an XM to XP centering ring, which was sanded down until it was flush with the LED base, then attached with a small wipe of super glue to prevent it from falling into the reflector.

 

 The driver was then modified by replacing the R200 resistor with a direct bridge, & replacing the stock LED wires with 22 gauge. No need to replace the switch wiring.

 I bench tested the driver at this stage, & measured just over 4 amps to the LED, using a single cell (25r) & long jumper cables & alligator clips. Installed in the light, the actual figure will be higher without the added resistance of the test leads.

 

 

 I also added some solder blobs to the battery side of the driver negative ring, so as the battery tube presses up against it when installed;

 

 Pill tightened down in the body & wired up;

 

 Light is assembled & checked for operation. As some other members have noted, with the resistor bridged, there is always a small amount of power getting to the LED;

A bonus Moon mode Smile   With the tail cap switch installed, it is not an issue.

Performance;

I measured throw at 10 meters, & also took a back-to-back measurement with my stock K50v2.

K50v2 measured a calculated 871 meters.

Courui measured 1166 meters.

Not bad for an afternoon's work! Smile

 

Beamshots;

A couple of quick mouse-overs between the Courui & K50v2 to show the difference in beam pattern. Distance is about 15 meters. (Mouse-over for K50v2)

 The hot spot is small, but searingly bright. Longer distance shots would do it more justice.

 

 

Edited by: FmC on 09/28/2014 - 07:17
bushwhacked
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Very nice mod. Thanks for sharing. I’m going to guess this will be something that a lot of people will do.

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Pulsar13
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One afternoon?!! This would take me a couple of weeks, LOL. Most of them trying to find stuff, I’m just not very organized.

Very nice mod BTW.

I do wonder how much current that clicky switch will allow. I imagine it would limit it a bit.

tatasal
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Great contribution..Thanks

MRsDNF
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Love it. It must look like a laser beam in the fog.

 

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.

 

JaredM
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Beamshots please :bigsmile: Beer

M4D M4X
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good work!

i like the tailswitch!

can you meassure the Apms over the switch please?

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!

Nightbird95
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Thanks for sharing this FmC! Smile

I think what I will be doing with my Courui is to ‘shamelessly copy’ this procedure. Silly

G0OSE
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Thanks for this, keeping an eye on anything courui at the moment – if mine ever gets shipped, 4 days later they are asking me for a few more days!

gamezawy
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nice mod thank you for sharing , any chance of Beamshots ?

FmC
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Thanks for the comments Beer

@ Pulsar13; The Omten switch is actually pretty good, djozz did a good job of trying to fry one recently in his switch testing.

@ JaredM; I’ll try to get some comparative beamshots up, but my camera is lacking the manual settings to do it well.

@ M4D M4X; Just for you, I took a reading without the battery tube & switch assy; Jumping a 25r through the multimeter showed a little over 4.5a. Obviously the meter eats up a little current, but it’s all I have to measure it.

tatasal
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Nightbird95 wrote:
Thanks for sharing this FmC! Smile

I think what I will be doing with my Courui is to ‘shamelessly copy’ this procedure. Silly

I will not be far behind you on this…haha. A new frontier for me

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tatasal wrote:
Nightbird95 wrote:
Thanks for sharing this FmC! Smile

I think what I will be doing with my Courui is to ‘shamelessly copy’ this procedure. Silly

I will not be far behind you on this…haha. A new frontier for me

A wise decision bro! Modding flashlights is a gratifying experience. And the good thing about being in BLF is that the people here are always willing to share what they know. Smile

Gj
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Very, very sweet! Cool Congrats.

tatasal
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Nightbird95 wrote:
tatasal wrote:
Nightbird95 wrote:
Thanks for sharing this FmC! Smile

I think what I will be doing with my Courui is to ‘shamelessly copy’ this procedure. Silly

I will not be far behind you on this…haha. A new frontier for me

A wise decision bro! Modding flashlights is a gratifying experience. And the good thing about being in BLF is that the people here are always willing to share what they know. Smile

I have noticed this willingness to share and the gratification posts by our generous members here since I joined BLF. Right on, bro. Beer

FmC
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Updated OP with beamshots. Sorry about the short range.

Beer
tatasal
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FmC wrote:
Updated OP with beamshots. Sorry about the short range. Beer

That much throw for such a relatively small amount of total expense? It’s crazy, I would say.

Very nice pics, btw.

Ervin Anastasi
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very nice work FmC Beer
what numbers do you get @ 10 m?

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

pinkpanda3310
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Very nice. I particularly like the tail switch. Smile

  

FmC
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Ervin Anastasi wrote:
very nice work FmC Beer what numbers do you get @ 10 m?

340kcd

Somewhat short of 1 million, I’m afraid to say Wink

DB Custom
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Stick a UCLp AR lens in there and watch how high that throw number jumps. Wink

My dedomed XM-L2 is making 369.25Kcd.

Nice work on that tail switch, not sure all three points were necessary at under 5A, but you gave it the whole 9 yds at any rate. Makes me want to add a switch to my XM-L2 version. It’s currently sitting awaiting use with the battery tube screwed out to break connection. Would be nice to not have to do that!

nofearek9
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nice work

gaston01
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Congratulations! Very good work Wink thanks for sharing Smile

Sorry for my bad English…

DB Custom
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The switch in the tail cap is a brilliant idea, one of those that makes you say “Hmmm, why didn’t I think of that?”

Took about an hour to do what with getting everything out and putting everything away, and it’s just perfect! Positive lockout to keep the e-switch from draining the cells. The e-switch still works as expected and this is the icing on the cake.

Really appreciate you sharing the idea and pics.

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Nice mod and wonderful to see such a writeup. Thank you very much Smile

~ Ledsmoke ~

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[quote=djozz]

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bibihang
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FmC wrote:
As some other members have noted, with the resistor bridged, there is always a small amount of power getting to the LED

A bonus Moon mode Smile


Very nice mod FmC! Beer

I thought I am the only one getting this “moonlight mode” when it is off, so is it really normal? I did the same thing like you by bridging the sense resistor and I couldn’t get rid of this annoying “moonlight mode” when it is supposed to be completely off! I reflowed the LED a few times (wasted a few drops of my AS5 as well Flat Stare ) and even have changed it into a new XM-L2 just hoping to solve this issue but I still failed. It could be my soldering skill is poor but I have inspected every connection as carefully as I could but I didn’t notice anything strange though.

I see it as an issue… I even have created a thread here looking for opinions. Does anyone else have this issue? I couldn’t find other people experiencing this yet.

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Best mod I can think of for the Corui, and very smooth work on the tail switch, well thought out! And you would think that the 32mm Noctigon should be wide enough to provide clearance for any reflector, but no.., LOL

DB Custom
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bibihang, if I remember correctly there was some talk about some drivers not liking the sense resistor completely bridged in that it messed with the PWM to the extent that it wouldn’t completely shut off, not recognizing the off level through the e-switch. There needs to be some resistance for the driver to recognize off.

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Great mod!

Back when I did my light my approach to the lack of lockout was very similar to what I did in the "retard light". I made twisty "switch".

Copper plates soldered to the battery circuit board and fujick under (added some extra JBweld when I did the tailcap).

I also added lots of grease to the threads after it was done.

Difference between good contact and complete lockout is half a turn. Smile

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Hopback
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Nice job FmC!

Threads like this annoy me though Sad I ordered my Courui 10 days ago and its not fair that everyone else is playing with their lights and I dont have one…

I’m going off to stamp my foot and sulk now.

DB Custom
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Hopback, I’ve had both of mine for several months or longer.

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