D.I.Y. Illuminated tailcap

1808 posts / 0 new
Last post
Helios-
Helios-'s picture
Offline
Last seen: 1 year 5 months ago
Joined: 01/18/2012 - 21:12
Posts: 2099

20mm

https://oshpark.com/shared_projects/UxcU5aMH

I went for a second slot. Party I liked the idea of slots so that we can solder the switch in from the spring side and keep soldering iron away from the plastic switch.

I’m debating if it might be nice to move the resistor and / or led out, away from the switch a bit. Moving the soldermask (or lack of soldermask really) for through hole led is a bit annoying.


Counterfeit 18650s, 2,<a href=“http://

pilotdog68
pilotdog68's picture
Offline
Last seen: 2 weeks 5 hours ago
Joined: 05/30/2013 - 23:31
Posts: 6422
Location: Held against my will in IOWA, USA

Ordered!

Hopefully the $89 “Super Swift Service” is worth it….

My Favorite Modded Lights: X6R, S8 , X2R , M6, SP03

Major Projects:  Illuminated Tailcap, TripleDown/TripleStack Driver

Helios-
Helios-'s picture
Offline
Last seen: 1 year 5 months ago
Joined: 01/18/2012 - 21:12
Posts: 2099

$89 super swift? Shocked Really?
Do you hate waiting that much?

One of my favorite things with oshpark is free shipping.


Counterfeit 18650s, 2,<a href=“http://

WarHawk-AVG
WarHawk-AVG's picture
Offline
Last seen: 11 months 1 week ago
Joined: 01/04/2014 - 06:47
Posts: 5071
Location: H-Town

Yikes…you paid $89 for 3 $3.10 boards?

daggum!

Helios-
Helios-'s picture
Offline
Last seen: 1 year 5 months ago
Joined: 01/18/2012 - 21:12
Posts: 2099

Honestly I would recommend against super swift, asking if oshpark can cancel it and refund you. Oshpark custom service is pretty good. support@oshpark.com

The plated slots are not guaranteed, not officially supported, meaning each time you order a board that has a plated slot there is a risk that the slot will not be made. Even if it was made correctly in a previous order.

Oshpark: Internal cutouts and slots.

Oshpark wrote:
Not Supported:

We can not guarantee the following features will be fabricated correctly, even if included on the design as described below. They should only be added at the user’s risk. That said: The fab will typically include them as intended if you follow the guidelines below.

[…]

Plated slots (larger than 40 mil)

The fab looks for the following indicators when scanning for plated slots. As mentioned above, there is no guarantee that this call out will produce the expected results, and the use of plated slots is discouraged.

Even if you do everything right the fab can miss it.


Counterfeit 18650s, 2,<a href=“http://

pilotdog68
pilotdog68's picture
Offline
Last seen: 2 weeks 5 hours ago
Joined: 05/30/2013 - 23:31
Posts: 6422
Location: Held against my will in IOWA, USA

Oops, guess I missed a winky face somewhere up there

Wink

My Favorite Modded Lights: X6R, S8 , X2R , M6, SP03

Major Projects:  Illuminated Tailcap, TripleDown/TripleStack Driver

Helios-
Helios-'s picture
Offline
Last seen: 1 year 5 months ago
Joined: 01/18/2012 - 21:12
Posts: 2099

I bet there is a very good chance oshpark can cancel it and refund you. Just email them at support@oshpark.com
Oshpark custom service is friendly, there is nothing to lose.


Counterfeit 18650s, 2,<a href=“http://

Helios-
Helios-'s picture
Offline
Last seen: 1 year 5 months ago
Joined: 01/18/2012 - 21:12
Posts: 2099

pilotdog68 wrote:
Oops, guess I missed a winky face somewhere up there Wink
Do you mean you were just joking, and did not pay for super swift? If so, you got us! Big Smile


Counterfeit 18650s, 2,<a href=“http://

pyro1son
pyro1son's picture
Offline
Last seen: 1 month 2 weeks ago
Joined: 03/21/2013 - 08:18
Posts: 432
Location: UK

Lets have a look at these clear switch boots, I’m interested in the idea.

Pastebin                                      &nbs

Halo...
Halo...'s picture
Offline
Last seen: 4 years 8 months ago
Joined: 12/15/2011 - 02:39
Posts: 3304
Location: Halo island

Transparent tail caps are available at cnqg. cnqualitygoods > Tail Cap
Haven’t seen anyone else carry them.

pilotdog68
pilotdog68's picture
Offline
Last seen: 2 weeks 5 hours ago
Joined: 05/30/2013 - 23:31
Posts: 6422
Location: Held against my will in IOWA, USA

Helios- wrote:
pilotdog68 wrote:
Oops, guess I missed a winky face somewhere up there Wink
Do you mean you were just joking, and did not pay for super swift? If so, you got us! Big Smile
:bigsmile: Party

My Favorite Modded Lights: X6R, S8 , X2R , M6, SP03

Major Projects:  Illuminated Tailcap, TripleDown/TripleStack Driver

pilotdog68
pilotdog68's picture
Offline
Last seen: 2 weeks 5 hours ago
Joined: 05/30/2013 - 23:31
Posts: 6422
Location: Held against my will in IOWA, USA

Oshpark just made my day!

Here is the email I just got from them:

Quote:
Hi! We had some free room on one of our Super Swift Service panels,
so we took the opportunity to give you an upgrade.

Your affected orders are: * Tail switch with led 20mm copy

The Super Swift Service drops your expected fabrication time from 12
calendar days to just 5 business days. The same fabs manufacture the
Super Swift panels as our normal panels, so you can expect the same
excellent quality.

Only fabrication time is affected, so the shipping times and method will
remain the same.

Thanks for using OSH Park!

My Favorite Modded Lights: X6R, S8 , X2R , M6, SP03

Major Projects:  Illuminated Tailcap, TripleDown/TripleStack Driver

pyro1son
pyro1son's picture
Offline
Last seen: 1 month 2 weeks ago
Joined: 03/21/2013 - 08:18
Posts: 432
Location: UK

Halo… wrote:
Transparent tail caps are available at cnqg. cnqualitygoods > Tail Cap
Haven’t seen anyone else carry them.

Shall see how this project goes. Might need to get some of those.

Pastebin                                      &nbs

pilotdog68
pilotdog68's picture
Offline
Last seen: 2 weeks 5 hours ago
Joined: 05/30/2013 - 23:31
Posts: 6422
Location: Held against my will in IOWA, USA

pyro1son wrote:

Shall see how this project goes. Might need to get some of those.

The basic concept is tested as working, but it definitely takes some tweaking. You’ll need to slightly modify your driver in addition to having this board. Read this thread for more info.

My clear caps made it to Chicago, so they should be here very soon. I’ll post pics when I get it fully assembled.

My Favorite Modded Lights: X6R, S8 , X2R , M6, SP03

Major Projects:  Illuminated Tailcap, TripleDown/TripleStack Driver

ImA4Wheelr
Offline
Last seen: 1 month 3 weeks ago
Joined: 02/03/2013 - 14:51
Posts: 7933
Location: SC

This is pretty cool.  So good to see you and Helios- turning your idea into reality. 

Now that I am nearing the completion of a project, I will order some of these boards and experiment with this too.

WarHawk-AVG
WarHawk-AVG's picture
Offline
Last seen: 11 months 1 week ago
Joined: 01/04/2014 - 06:47
Posts: 5071
Location: H-Town

pilotdog68 wrote:
Oshpark just made my day!

Here is the email I just got from them:

Quote:
Hi! We had some free room on one of our Super Swift Service panels,
so we took the opportunity to give you an upgrade.

Your affected orders are: * Tail switch with led 20mm copy

The Super Swift Service drops your expected fabrication time from 12
calendar days to just 5 business days. The same fabs manufacture the
Super Swift panels as our normal panels, so you can expect the same
excellent quality.

Only fabrication time is affected, so the shipping times and method will
remain the same.

Thanks for using OSH Park!


Wow…SWEET!!!!!!
pilotdog68
pilotdog68's picture
Offline
Last seen: 2 weeks 5 hours ago
Joined: 05/30/2013 - 23:31
Posts: 6422
Location: Held against my will in IOWA, USA

Clear switch covers were delivered today! I did a mock-up with my test rig and my new ultra-bright leds. I’m still waiting on the 20mm boards to get the final product.

This is with a 1.5mm through-hole led tucked right up under the cover. I think if I keep it lower in the body the light will spread over the cap much better. It’s also way too bright with the current resistor set, that will be changed later.

My Favorite Modded Lights: X6R, S8 , X2R , M6, SP03

Major Projects:  Illuminated Tailcap, TripleDown/TripleStack Driver

Firelight2
Firelight2's picture
Offline
Last seen: 1 hour 14 min ago
Joined: 04/08/2011 - 15:17
Posts: 4236
Location: California

Wow awesome job!!!

Now we just need RMM to start selling preassembled kits and drivers. Or make it an option on his modded lights. 0:)

pyro1son
pyro1son's picture
Offline
Last seen: 1 month 2 weeks ago
Joined: 03/21/2013 - 08:18
Posts: 432
Location: UK

OK I am definitely going to need to do this to some of my solarforce lights.
Can we see some photos of the resistor added to the driver and the switch built?

Pastebin                                      &nbs

WarHawk-AVG
WarHawk-AVG's picture
Offline
Last seen: 11 months 1 week ago
Joined: 01/04/2014 - 06:47
Posts: 5071
Location: H-Town

Nice…lighted tailcap…how cool is that!

djozz
djozz's picture
Offline
Last seen: 6 hours 48 min ago
Joined: 09/07/2012 - 17:04
Posts: 17673
Location: Amsterdam

Missed this sofar, pretty cool, going to do this, thanks fkr making this happen, pd68&Helios!

pilotdog68
pilotdog68's picture
Offline
Last seen: 2 weeks 5 hours ago
Joined: 05/30/2013 - 23:31
Posts: 6422
Location: Held against my will in IOWA, USA

I have more good news for people looking to try this. Big Smile

I added resistance at the tail, and put my DMM in-line to take some draw measurements.

The resistor on the driver is 560ohm, and in-line with the tail led is 4.7kohm.

Moon mode for the main Nichia LED draws 10.6ma.

With the light off, the tailcap LED draw is only 0.29 milliamps Star

So assuming you use a 2500ma battery, and assuming the tail LED is left to run 24/7, you will lose roughly 8.4% of your battery capacity every 30 days, and it will run for a full year before completely exhausting your battery.

Obviously I still wouldn’t put this in a light that is never used, because there is clearly no low voltage protection, it will drain your battery to unsafe levels if left unattended. But I think it’s pretty awesome for a bedside light or some other light that gets used and recharged regularly.

Here’s the best part: when i took the measurements above, the LED I’m using is still FAR TOO BRIGHT.

It is clearly seen glowing under the clear tailcap even in direct sunlight, and in a dark room you can see the glow on the ceiling.

I expect that the current draw at my optimum brightness level will probably be 0.1ma or even lower.

My Favorite Modded Lights: X6R, S8 , X2R , M6, SP03

Major Projects:  Illuminated Tailcap, TripleDown/TripleStack Driver

antoninodattola
Offline
Last seen: 2 years 1 month ago
Joined: 11/22/2013 - 14:19
Posts: 103
Location: Italia

Why not try also led with size 0805?
you could draw pad SMD resistor and LED, to save space;
Helios Thanks for your great work!

http://www.mouser.it/ProductDetail/Kingbright/APT2012SECK-J3-PRV/?qs=sGAEpiMZZMseGfSY3csMkTeYsK%252b3NnHeAS8V4xHV944%3d

 

 

pilotdog68
pilotdog68's picture
Offline
Last seen: 2 weeks 5 hours ago
Joined: 05/30/2013 - 23:31
Posts: 6422
Location: Held against my will in IOWA, USA

The pcb is designed to use an 0805 resistor, and your choice of through-hole or 0805 Led. I used a through-hole because it’s easier to get the light up to the tailcap, whereas the light from an smd led might be blocked by the switch housing and spacer ring.

My Favorite Modded Lights: X6R, S8 , X2R , M6, SP03

Major Projects:  Illuminated Tailcap, TripleDown/TripleStack Driver

WarHawk-AVG
WarHawk-AVG's picture
Offline
Last seen: 11 months 1 week ago
Joined: 01/04/2014 - 06:47
Posts: 5071
Location: H-Town

I wonder what it would take to have a red, yellow, green (or whatever color you wanted) to activate at certain voltage levels…aka tail cap tells you the voltage

I know simple is better but just brainstorming here…

Wait..if it has enough power to run the LED, why would it not be enough to toggle a MOSFET?

pilotdog68
pilotdog68's picture
Offline
Last seen: 2 weeks 5 hours ago
Joined: 05/30/2013 - 23:31
Posts: 6422
Location: Held against my will in IOWA, USA

There is a bleeder resistor on the driver that keeps the mcu shut off. Read through the last page of the thread listed in the OP for more info.

My Favorite Modded Lights: X6R, S8 , X2R , M6, SP03

Major Projects:  Illuminated Tailcap, TripleDown/TripleStack Driver

WarHawk-AVG
WarHawk-AVG's picture
Offline
Last seen: 11 months 1 week ago
Joined: 01/04/2014 - 06:47
Posts: 5071
Location: H-Town

ah…did miss that…thanks pilotdog68

Antenne
Antenne's picture
Offline
Last seen: 3 weeks 4 days ago
Joined: 01/13/2015 - 15:05
Posts: 240
Location: Germany

Have you tried 2 red LED in series? The voltage could probably be enough for them and you would get low voltage protection this way…
P.S.: I’ve thought about this – beside 2 LED’s you could also use one or more ordinary diodes (like SMD 1N4148) in series to the tailcap LED (s) to adjust the cutoff voltage to a useful level – thus getting a signal for low voltage as a bonus (LED goes out).

pilotdog68
pilotdog68's picture
Offline
Last seen: 2 weeks 5 hours ago
Joined: 05/30/2013 - 23:31
Posts: 6422
Location: Held against my will in IOWA, USA

Hmm that would be awesome, but I didn’t even know that was a possibility. It’s above my knowledge level.

My Favorite Modded Lights: X6R, S8 , X2R , M6, SP03

Major Projects:  Illuminated Tailcap, TripleDown/TripleStack Driver

djozz
djozz's picture
Offline
Last seen: 6 hours 48 min ago
Joined: 09/07/2012 - 17:04
Posts: 17673
Location: Amsterdam

the 805 SMD red leds that I found are all 2-2.2V, my first thought is that two in series would give a 'your battery is not completely full' warning Smile . But at the sub-mA currents the voltage may be well lower than that...

Pages