Courui + 86mm KD reflector + camera parts; Say Cheese!!

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FmC
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Courui + 86mm KD reflector + camera parts; Say Cheese!!

 Following on from LinusHofmann's thread, I ordered the big KD reflector, along with the camera lens hoods/adapters that he linked in his OP.

 They all turned up during the week, so I was eager to see what needed to be done to get it all together.

I have a modded D01 that I prepared earlier, which is already a killer thrower. The only change made since that thread is the addition of a Fet driver, although the performance is still the same @ 340kcd.

 Here's all the parts from Linus' shopping list, plus I threw in a lens protector;

The KD reflector was flawless, & dwarfs the stock D01 reflector.

I needed to remove some material from the OD of the reflector lip, in order for it to fit into the larger of the two hoods. It could be done with a file, but you better take a cut-lunch with you...

Now that I could trial-fit all of the parts, the entire assembly comes up just a few mm too short.

There's no chance of fitting a regular lens & 'O' ring, as the reflector is sitting almost flush with the top of the upper hood.

In addition to this, I didn't like the idea of cutting the original bezel in half to use to clamp the assembly to the body.

I rummaged through some parts I had, & found a 74mm lens filter assembly that I had from when I was trying out some different lenses. The female thread, although a slightly finer pitch, fitted onto the D01 body, so after some more measuring, I figured that I could get the ideal height by attaching the filter ring to the lower hood.

I sanded the threads off the lower hood;

& also sanded down the ring a little;

Until I ended up with this;

The lower hood & ring were then JB welded together;

In order for the reflector to sit down flush onto the MCPCB, I also had to relieve the inside lip of the upper hood;

And finally, we end up with a completely reversible solution, with enough height to install a more durable lens & 'O' ring if one desires;

 

What the hell is that in there?!? That there, is my centering ring, made from an old 20mm driver. It fits over the modified XM-XP centering ring that was already in the light;

Here's the finished light, using an 86mm UV filter for the lens;

 

Soooo, was it worth the effort?

I took a back-to-back comparison, measured @ 10m;

Stock reflector, 340kcd.

Quick reflector change whilst topping up the batteries;

KD reflector, 625kcd.

 

Yes. 625 kcd.

Beer  Beer

 

Thanks for reading!

 

_update_

Beam shots, because I know someone will ask for them;

Mouse-over, KD reflector, mouse out - standard reflector.

 

Beer

Edited by: FmC on 05/24/2015 - 06:30
cajampa
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Nice mod FmC Smile
I hope i will do something like this one day.

You didn’t say what led you used, so what what was it?

Where do you find the clear XM to XP centering ring?

FmC
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cajampa wrote:
Nice mod FmC Smile
I hope i will do something like this one day.

You didn’t say what led you used, so what what was it?

Where do you find the clear XM to XP centering ring?

I believe it’s an XP-G2 R5 1A.

Those rings are available from FT, & RMM. I just sanded it down so it was flush with the LED base.

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Wow. You guys are so creative with what you come up with. That is a good comparison shot with the standard reflector. I love it when I get sacked.Smile

 

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.

 

cajampa
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FmC wrote:
cajampa wrote:
Nice mod FmC Smile
I hope i will do something like this one day.

You didn’t say what led you used, so what what was it?

Where do you find the clear XM to XP centering ring?

I believe it’s an XP-G2 R5 1A.

Those rings are available from FT, & RMM. I just sanded it down so it was flush with the LED base.

Aha thanks, those i know about (don’t have them yet though), it just looked so different when sanded down Smile

You could drop in a XP-G2 S4 2B, that one is many flux bins higher (I think it goes R5-S2-S3-S4 in flux bins, so 4), it should give a substantial improvement in throw. IOS & MTN has them Wink

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Updated OP with some beam shots.

Please excuse my pos camera….

johny723
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very creative. What is the best place to buy a courui big head? I want to do this mod. The only difference is using a slightly taller hood that should give me some more clearance. Something like this- http://www.ebay.com/itm/82mm-Tele-Metal-Screw-in-Lens-Hood-For-Canon-Nik... it is 36mm tall, the stock one is 25mm tall. It has more than enough height to accommodate an o-ring + a proper lens or another. If it is too high, I can place some copper washers under the emitter star.

sedstar
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thats really cool…

i like that reflector…i cant wait till i get a little better at scratch building stuff, lol…

everything i make now? has too much duct tape and plastic PVC pipe and fittings, lol…

With enough black coffee and cigarettes? all things are possible…

I am currently still shipping… REAL GENUINE CREE xp-g emitters, the classic… brace yourself? as low as 20 cents apiece!! Check out the SALES THREAD, everyone is happy… then PM me

SALES THREAD:
http://budgetlightforum.com/node/52528

if you are into reloading? this is my site… I inherited the remains of what was once arguably the best reloading site on the internet… its the “BLF” of reloading sites…

http://reloadbench.freeforums.net/

if you think night vision would be cool? It IS… this site i am a member of, and its basically the “BLF” of home made scratch-built digital night vision. They are at the leading forefront of advanced DIY for digital night vision, and thats gun mounted or handheld… builds rival and exceed commercial offerings…

http://nightvisionforumuk.com/

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Love it man, the light looks great!

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Nice neat finish FMC. Great work.

  

johny723
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we need beamshots from a further distance. Could you take some photos of the KD vs stock reflector from 200m or so? Thanks!

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is a way to do similar project ,if you dont have the tools to remove material from the reflector ?

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Awesome mod!!! Beer Beer

How did you protect the reflective surface when you were removing material from the edge? Did the KD reflector came protected with plastic as in the photo? What did you use to hold down the centering MPCB to not fall into the reflector?

Thanks!

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nofearek9 wrote:
is a way to do similar project ,if you dont have the tools to remove material from the reflector ?

I’m sure there’s other sizes of adapters available that would do the trick.

I’ve already ordered a set of these for other projects.

AlexGT wrote:
Awesome mod!!! Beer Beer

How did you protect the reflective surface when you were removing material from the edge? Did the KD reflector came protected with plastic as in the photo? What did you use to hold down the centering MPCB to not fall into the reflector?

Thanks!

The reflector had a protected film over the opening, which I managed to keep on there through the machining process. I cut it carefully with an exacto knife around the tip of the lip, so it didn’t get jagged on the cutter. The centering ring is held on by a couple of dabs of super glue. As for longer beam shots, I’ll see what I can do during the week.

Thanks Beer

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Great build. Gotta love those photographic components. 

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

 

FmC
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johny723 wrote:
we need beamshots from a further distance. Could you take some photos of the KD vs stock reflector from 200m or so? Thanks!

I got around to taking some long-distance shots this evening. Sorry, but no comparison shots with the stock reflector.

There's a concrete pump tower up the road from where I work, which is visible by day. Google Earth tells me it's about 375 meters from the back of my workshop, where I took the pictures;

Day / Night pictures for reference;

It wasn't quite dark when I took the pictures, & also there's a lot of light pollution in the area...

Here's a mouse-over of the night shot to the pump tower with the KD reflector Courui;

~1/4 mile? No problem...

 Prior to this, we were lighting up some of the near-by Gum trees, that were full of Crows settling in for the night. They hated it, & left the tree en mass, each time the beam hit them.

 We had literally hundreds of Crows flying around, & dodging the beam mid-flight.

 'The Boys' at work were suitably impressed Smile 

Beer  Beer

cajampa
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Good shot Smile

Long beam shots are always interesting.

johny723
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impressive!

johny723
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what emitter would be a better choice in this reflector? An overdriven dedomed xm-l2 or xp-g2?

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XML\XPL will give you a larger beam & more lumens, possibly at the expense of a little throw.

I'm yet to try an XML in this setup.

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I did some calculations and according to my approximate results the “surface brightness”( I dont know if that is the right terms) of a xm-l2 driven at 6 amps is virtually the same as the surface brightness of a xp-g2 driven at 5 amps and even higher if you push the xm-l2 to 7amps. But these are just my assumptions based on graphs and readings made by other members http://budgetlightforum.com/node/22570?page=1
Could you please measure the current to the xm-l2 and throw readings of the next setup and take a beamshot for comparison??? Thanks!
Is there any driver capable of delivering 7amps to xm-l2 emitters? Does anyone actually push them so hard???
Sorry for a little off-topic, I dont want to hijack your thread, we can discuss it in my thread and keep yours clear! http://budgetlightforum.com/node/39812

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No problem, we’re all about OT here…

I’d like to build up another one with XML/XPL, but that may be a little while off.

The problem you are going to find, as I alluded to in your other thread, is finding an XML/XPL that will cope with those current levels.

There’s plenty of drivers that will do it, but you are going to have to mod the D01 for a serial setup, which is a fair bit more work as well.

cajampa
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You don’t need a XM-L2 that can take hi current like the old ones. the new XM-L2 U4 is much more efficient, so even with the lower current use it will still out throw the lower flux bins that can take more amps.

I built a UF-1504 with the XM-L2 U4 1C dedomed, that i run fully DD without any driver at all. and it is much stronger (almost 1/3 LOL than my 1504 with a XP-L V6 1A that takes more amp & get much hotter but is weaker than the new U4 Smile

And johny723, check out n10sivern’s test of the newest high flux bin emitters in the 1504 to see there potential Wink
As you can see the XP-G2 S4 2B is even stronger, but with a smaller spot & less lumens.

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Yep, it would be good to see some graphs/back to back tests done on these new U4’s / S4’s, compared to the earlier emitters.

I have another big KD reflector in-bound, & am thinking of putting it in different host, with a buck driver setup…

Beer
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Nice, looking forward to see the host you are going to pick, i hope its a cheap one Wink

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It seems that 750kcd would be piece of cake for this light with newest bins.

That KD reflector is probably used in Eagletac M25C2 Turbo.

An excellent light for mountain rescue crews.

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FmC wrote:
I didn’t like the idea of cutting the original bezel in half to use to clamp the assembly to the body.

I rummaged through some parts I had, & found a 74mm lens filter assembly that I had from when I was trying out some different lenses. The female thread, although a slightly finer pitch, fitted onto the D01 body, so after some more measuring, I figured that I could get the ideal height by attaching the filter ring to the lower hood

as well i dont like to cut the original bezel/ring , i dont know if this : http://www.ebay.com.au/itm/291553614311?_trksid=p2057872.m2749.l2649&ssP...
will make the trick.

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nofearek9 wrote:
as well i dont like to cut the original bezel/ring , i dont know if this : http://www.ebay.com.au/itm/291553614311?_trksid=p2057872.m2749.l2649&ssP... will make the trick.

That looks as though it would do the job.

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we will found out in 3-4 weeks Smile

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an update the ring above worked fine BUT after my second attemp failed to remove the extra material from the reflect (i ended up with 2 damaged reflector) we need to find a source pre-milled reflectors,its not easy job to do it without the correct hardware Sad

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nofearek9 wrote:
an update the ring above worked fine BUT after my second attemp failed to remove the extra material from the reflect (i ended up with 2 damaged reflector) we need to find a source pre-milled reflectors,its not easy job to do it without the correct hardware :(

Sorry to hear that. It would be great to source an 86mm I.D. hood, then it would be a very easy mod.

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