Many of the procedures I document here (Especially using the table saw and working with Li-ion batteries) are dangerous and should not be replicated unless you are willing to assume responsibility for any injuries and damages that may result.
******* WARNING *******
NOTE: It's not looking like I will have the time to complete this build. I just don't see enough blocks of time before the contest ends. So I will just work on building this light as if I have no deadline. I have family and other responsibilities that I just can't let this project get in front of. I do hope to find some time and also have some lucky breaks (meaning, things don't break and actually go as planned).
Summary/Index:
I've settled on using the Oxygen Tank. It will be used for making the head which will house a Defiant XML Spotlight reflector and an MT-G2 emitter. I will leave the dome on in order to make the light have a nice general purpose beam pattern that will light wide and fairly far. The battery tube will hold 12 18650 cells in a 3P4S formation. It will be a side switch.
Imagining and deciding on a tank and a design. Burned a lot of time doing this.
I could not imagine a design that inspired me on the Scuba Tank that would not be too ambitious to build in the time available.
Lots of problems to work out ahead of time once I decided on the Oxygen Tank and a design. Still working on some of them in my head.
Machining uniform fins and such into the head will be tough due to the size.
Anodizing, because I have never done it.
Failures:
My first cut into the tank did not go smoothly. The tank shifted at some point while rotating it by hand during the cut. The cut can be seen in Post 17. Luckily, I had allowed for this type of problem by cutting the length of the head oversized.
Original Post:
Not sure what I will do yet. Still have the below scuba tanks and oxygen tank sitting around wanting to be useful. So I will commit to using one of them in some way. What ever I do, I will be keeping it simple as time is by far the most limiting resource.
I get your point. The more I think about this, the more I'm realizing the sheer size of the tanks will create complications. I'm finding my self wanting to go all out with the big scuba tank, but know I would regret that decision. I'm thinking going with the oxygen tank because they are so plentiful and cheap. Maybe I should try to make a light with it in a way that will help enable average jill's and joe's make a large reflector light on the cheap.
^
Yes! I agree. Those scuba tanks really make my imagination fire up. So far, everything I think of will just be too heavy for any of my uses. So I guess, I will be going with the much smaller oxygen tank. I’m trying to not blow hundreds of dollars on this build. So I’ve been scrounging around my shed and came up with a 1.5” schedule 40 aluminum pipe. It will fit 3P 18650’s and is long enough for 4S. I really wanted to go 4P4S, but I need to watch my spending on this as I said.
Thank you Sir for your vote of confidence. It won’t be anywhere near the league of an O-L build, but it will be inspired by you and your many masterpieces.
The procedures I document here using the table saw is dangerous. It is not designed to be used this way and things can easily go wrong, resulting in injuries and damages.
******* WARNING *******
my first cut didn't go well. I didn't hold my focus good enough to make a nice clean cut. Part of that was due to me pulling the tank back repeatedly to see how deep it was getting cut. I need to make a jig to help hold the tank steady as a manually rotate it.
Tried making a jig with 2x4's and PVC, but it will not work for the some of the cuts and felt too rickety. Gonna try just using 2x4's and screws next. Any suggestions?
A miter saw makes it easier as the blade / carriage moves and the work stays stationary. Other than that I can’t think of how to improve…. The real trick is how to keep the tube from moving right/left…. A stop of some kind on the longer left side and nothing between the blade and the shorter cut off piece.
Do you have a hole saw the size of the tank diamter? Make a ring that can be mounted and rubs on the left table edge? Cut a ring using a saber saw? Make in two halves and screw halves together? Use 2x stock?
There, I had an idea
I use my Makita miter saw more than my table saw, unless I’m ripping something. Those Diablo blades are nice and if you cut a lot the parent company Freud blades are a touch finer. There are many blades with specialized uses. I have several. The hook angle of the carbide tip varies a lot as well as the tooth count between design uses…
Just an idea, you’ll probably think of a better one. Cut two strips to fit the cross cut guide grooves and screw them to the bottom of two 2 x 4’s so the strips both fit in the guide slots as well as true and even so that the cylinder can rest between them square to the blade and just above the table. Remove the fence and clamp them to the table with the back 2 x 4 in the same place it is now. Screw a stop block to the 2 x ’s to set the length, and start the cut with the blade lowered. Power on and slowly raise the blade, rotate the cylinder to finish the cut and lower the blade. I’m sure you know this but for others the carbide teeth are brazed to the blade body and a blade jam can not only ruin your day but instantly rip several of the teeth right off so any guides must be set absolutely square to the blade. A 10” blade has a lot of angular momentum and when it jams(kick back) something usually goes flying with enough force to break bones, shatter windows, or rupture a spleen.
