Hi all,
Went to HF and purchased the 3D size light. Its the 95LED 3D flashlight
http://www.harborfreight.com/11-1-4-quarter-inch-95-led-flashlight-66567.html
DX SST-90 SMO 7.3cm reflector drops right in with zero machine work…
http://www.dx.com/p/sst-90-smooth-aluminum-reflector-7-3cm-diameter-47996#.VQctJE10ycI
I used a Maglite D heatsink for it and a Maglite D switch too, but you can use the stock switch too.
XML2 in there now at 3A and generating 145K lux continuously.
Best,
bigC
Can you post some pictures of the finished light please. Also how did the maglite heatsink fit in.
The light looks similar to models on DX, KD etc. Nice that the SST90 reflector drops right in. How much work was it to swap in the M@G switch? Seems like a good candidate for an XHP50 or MTG2 w/ the right driver.
I gave the light away yesterday to an uncle that’s going out of the country Today and needed the light to take with him. So, don’t have it anymore. Plus, I still cant figure out how to post pictures here so I normally put videos.
The DX SST-90 Reflector needs no machining. The opening is small but if your heatsink has a pedestal you can keep the opening as is. Myself; my heatsink was flat so I got a drill bit that starts small and opens up. The base of the SMO 73mm reflector is completely flat so its ubber easy to make the opening bigger.
The stock Mag D switch fits perfect inside this HF host. Perhaps a bit more snug, but something I actually preferred.
bigC
I have 2 of the HF 109 LED bigger head shower lights too. While the bezel is about 1/2 inch bigger surprisingly the SST-90 reflector actually fits this smaller 95 LED head better and you get the added bonus of using your spare Mag switches or heatsinks
BigC
The head to body threading isn’t the same as the Mag by chance is it?
Nope. But with the 3D 95LED shower head light you get the basically a 3D body with turbo bezel. Then just drop-in the 73mm SMO bezel, Mag heatsink, and wire stock switch or use Mag switch.
bigC
If you get a Maglite body the diameter is or appears identical in size to the HF 3D light, so you wouldn’t even be able to make threads on it or use epoxy to glue them together (I tried).
The factory HF 95LED body is slightly less than 3in bezel it has though. What this allow is for you to cut the 3D tube and you can easily JB weld the tube to the 3in bezel afterwards. Than just make a side hole for the switch.
I actually cut my 3D body to 1D size. Then JB welded the bezel to its 1D size body since I cut off the threads section where bezel/body would screw on. Just made a side hole for the Mag switch and walllah, it worked.
Maybe I will try & cut to a 2D size next for another build.
bigC
very interesting… might need to head to HF. Thanks for the info!
Well my reflector finally arrived… and it doesn’t quite fit. 
Looks like I’ll need to do some sanding and filing it seems like it could work
They can still be epoxied onto that 3D HF host. That’s what I did. Just stick the reflector inside the bezel and epoxy it even if you cant get it to screw all the way.
bigC
Its summer and I finally have time to post the results of this build. The host itself isn’t as good as a mag, but the quality is adequate. The reflector wasn’t quite a direct drop-in but it didn’t take too much work to make it fit. I also enlarged the opening to fit the 16mm star and bolts. Over all it turned out to be a very clean build… and this thing can throw!
^ Nice work and report kicken_bright. You really machined off a lot of material on that reflector. It looks like you really had to get close to going through the reflector. How close do you think you got to going through?
I didn’t have to take much off. That lip/ridge was there before. I just took off maybe .5-1mm all the way around with a hand file.
Seeing how nice you got your bezel to fit all the way in with top bezel lens I am gonna have to try and trim some off on my next one. I already epoxied/JB Weld my bezel on. So, no going back. Mine I cut and JB Welded the body to the heatsink since I cut it to be 1D size. Wish I had pictures of it too, but It is in rural Mexico now to a great uncles Lemon Orchard he needed a long thrower but compact (hence why I made it a 1D size).
I still have all the parts to build me another 3D HF hosts too.
Love the simple Copper plumbing end-cap you used. Inexpensive and great way to put it to use.
BTW: I got with mine and XPL Dedomed 6K tint with 5A~ to LED 240K lux.
Is That an XML2? What Amps?
You definitely must be getting 240K lux and likely more than me.
BTW: for those on the fence with this build. This reflector is huge and focuses almost any LED you can throw at it. The only one I haven’t gotten a nice tiny spot was when I stuck an XHP70 in this DX reflector. Other than that XPG2, XPE2, XML2, and my current set-up is MTG2 you get perfection.
bigC
It is an xp-g2 run by a 4 x 7135 driver. So its either 1.4 amps or about 1.5 if its a new one… I’m not too sure. Either way, I would say it is north of 100K lux… but I don’t have any way to verify.