Hello and welcome to my build thread for the 2017 5th Annual BLF / Old Lumens Scratch Made Light Contest which is a competition where BLF members take part by making a flashlight or set thereof from scratch and was started by now deceased member Old Lumens who loved modding and making flashlights.
There are two categories, Machine made and Hand made.
Again I will be entering the hand made category and making the light(s) using only small hand held tools.
This years flashlight will be made from copper and wood, C101 1.2mm copper sheet and Indian rosewood.
I have never worked with wood before so this should be an interesting experience.
Incorporating alternating stratis of copper & wood and be similar in size to a credit card although a lot thicker.
I have some stuff here but have ordered special materials for the body of the light and waiting for them to arrive, some members have no patience so I have made some images up with the concept I am planning.
The light will be a quad emitter setup for the main lumina powered by a 17mm 105c 3A Nanjg driver and also have auxiliary red and UV emitters operated by a secondary momentary switch or mercury tilt switch so depending on how the light is positioned these will be on or off.
The main driver will be a Nanjg 105c 3Amp with MoppyDrv firmware and operated via a blue tritium momentary switch on top.
The light will be powered by a 1200mAh lithium polymer cell with a charger board built in and wired to a micro USB port.
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CRX Stratis Lumina Finished
This light has three modes of operation, a tritium momentary locator switch on top for operating the main quad Nichia emitters via the Qlite 3A driver giving a sustained maximum of around 1092lm, a glow in the dark momentary switch for operating the eight UV front emitters and a mercury tilt switch which automatically turns on the four bottom red LED's when the light is placed faced down or thereabouts.
Features:
Quad Nichia 219C D320 5000K Emitters
MTN 20mm Offset Quad DTP MCPCB
10621 Carclo Quad Spot Optic
34mm x 2mm Dual Coated ARC Glass
QLITE Momentary 3A Driver with Moppydrv
Dual Momentary & Mercury Tilt Switches
Ice Blue Tritium Locator Switch
Cyan Coloured Glow Details
1200 mAh Lithium Polymer Cell
TP4056 Micro USB On Board Charging
8 x 3mm 400nm UV LED's
4 x 3mm Deep Red LED's
CRX Etched Lettering
Copper & Rosewood Construction
Hand Made Leather Carry Case with Clip
Length - 86mm
Width - 52mm
Depth - 22mm
Weight - 250g
Max - 1092 lm
Time Taken - Approx 40 hours
CRX Stratis Lumina Runtime Graph:
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CRX SL Mini
This complementary light is much smaller in size for a more convenient carry and has two modes of operation with two momentary GITD locator switches on top, one for the front triple XP-G2 3D emitters giving a max output of about 392lm and one for the dual red LED's on the bottom of the light.
Features:
Triple Cree XP-G2 S4 3D Emitters
Noctigon 20mm DTP MCPCB
Mule
22mm x 1.2mm Dual Coated ARC Glass
Dual Momentary Switches
200 mAh Lithium Polymer Cell
TP5000 Micro USB On Board Charging
2 x 3mm Deep Red LED's
Cyan Coloured Glow Details
Copper & Rosewood Construction
Length - 59mm
Width - 38mm
Depth - 12mm
Weight - 75g
Max - 392 lm
Time Taken - Approx 7 hours
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CRX SL Micro
The SL Micro is a fun light that can be worn on a neck chain for brief illumination periods and has a single mode of operation via a brass twist bolt on top which switches on the three front XP-G2 2B emitters for a maximum output of around 360lm and comes with a kydex carry clip & chain.
Features:
Triple Cree XP-G2 S4 2B Emitters
Noctigon 20mm DTP MCPCB
Mule
20mm x 1.2mm Dual Coated ARC Glass
Brass Bolt Twist Switch
200 mAh Lithium Polymer Cell
TP5000 Micro USB On Board Charging
Copper & Rosewood Construction
Hand Made Kydex Carry Sheath
Length - 40mm
Width - 25mm
Depth - 12mm
Weight - 34g
Max - 360 lm
Time Taken - Approx 6 hours
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CRX Stratis Lumina flashlight set
Total Time Including Documentation - Approx 70 hours
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Well here it is, going from my imagination to reality this has been a fun, educational and sometimes very difficult build but also a great learning experience.
Thank you to everyone that watched, commented in the thread and sent personal messages, I really appreciate that
Some personal observations:
The CRX Stratis Lumina turned out fairly close to the original drawings I made up with the concept of having a front elevation the size of a credit card and I am happy with the outcome.
The light performs very well, to my expectations with one of my favorite Nichia tints and the automatic red LED's for quick close range illumination when the use of the main array is not necessary. The UV is also a nice feature to have here.
Running the light on full power, the large amount of flat copper heat sinks do their job very nicely with the mid layer heating first, the internal copper heat sink block saturating to finally spread to the copper back plate with the whole light eventually becoming warm
Looking back there are a couple of things I would have done slightly differently using other techniques but learning on these little creative journeys is half the reason I do it.
The SL Mini can easily be slipped in a jeans side pocket and again has enough power to be useful along with the very nice 3D tint and night vision preserving red LED's.
The SL Micro is just ridiculously small and fun for a rechargeable triple emitter hand made light and can be worn on a neck chain or kept in a pocket hardly noticed.
As usual with me, this project started off as one idea then grew into a little family all cut from the same stuff.
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The CRX Stratis Lumina Basic Layers Concept
This is my original idea for how the light will be made using alternating layers of copper and wood.
These images are measured, cropped and placed manually.
Going from left to right = bottom to top sequence of layer assembly.
Layers with the wood cut out.
Electrical components layout.
CRX Stratis Lumina should look something like this, all going to plan.
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Building the Lights
Below are the build highlights, clicking on the images will take you to the respective post for more information.
I like listening to music (and I use that term loosely ) when I build torches and have included some tracks in the various posts.
You don't have to play them if you don't want to
Indian Rosewood and C101 1.2mm Copper sheet arrivedCopper cut to rough sizes
Rosewood cut to rough sizes
Copper sandwich
Working on wood
Drilling holes for LED's, switches and USB port
Copper & wood pieces layout
GITD LED's
Drilling copper mid layer for wiring & marked out front plate
Rough components layout
Drilling fixing holes in the copper & wood
Experimental etching
Soldered standoff fixings together and attached to back plate
Started filing work on the edges to level up
Bodywork fitted together
Size indication
Drilling out front plate hole for optics
UV LED array for optic surround
Brass inserts for the switches & charger indicator installed
Temporarily illuminated to show effect
Charger indicator rod
Tritium switch made
Charger board installed
Red LED test
Brass Driver housing
Driver test
Charger & red LED test
Mercury switch test
SL Mini built
Switches, Quad and UV Array installed
Front glass and plates fitted
Made a leather carry case
Etched username into copper
SL Micro is born
Kydex holder made
Stratis Lumina Set Complete
Today's Tune:
Thanks for your support...
Looks great! I like the look of the polished copper, GITD switch and blackened finns
Is it really, really small??
‘cause I can’t see anything…
Nanotechnology!
How to Post Images on BLF // Many knives for sale (USA only)
How to move a thread
I haven’t even started yet. Tough crowd
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The bar is where you set it…
I’ll just put my glasses away then, Thanks for the update CRX.
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.
Sub
It ‘ll be good
- George
My Reviews : KDlight C8 / ThruNite Archer 1A V3 / Thorfire C8s / ThruNite TN12 (2016) / Utorch UT01 / Utorch UT02 / Jetbeam WL-S2 (xp-l) / ThruNite TC12 V2 / Massdrop Brass AAA / Manker LAD / Lumintop SD26 / ThruNite Mini TN30 (3x xm-l2) / Qualilite D81 / Nitecore MH20GT / Odepro TM30 / Klarus XT30R / Nitecore NU20 CRI / Ultrafire XM-L2 / Foursevens Mini MK II / Manker E02 / Manker E14 II / Teekland Flashlights / Lumintop Elfin / Thorfire S70S / ThruNite Neutron 2C / Jaxman M8 / KDLITKER C8.2 / Zanflare F1 / Nitecore Concept 1 / Emisar D4 / Astrolux MF-01 / ThruNite TC10 V3 / Amutorch JM70 (xpl hi)
Yep.
The Cycle of Goodness: “No one prospers without rendering benefit to others”
- The YKK Philosophy
I knew it would be Extraordinary and Small
Do you ever stop imagining things
For our good, I just hope you don’t
Good work on this!!
MY REVIEWS THREAD /// My Flashlight Collection ///
Mods: 1 / 2 // TIR: 1 / 2 // Others: Biscotti 3 + 1*7135 / Triple TIR w/ XP-G2 /// My Review's Blog (PT) /// OL Contest 2019 /// OL Contest 2020 /// GIVEAWAYs: 1 / 2
Carly Simon – Anticipation
(“It’s good that most people can’t remember their previous lives. Otherwise
things would be a lot more complicated than they already are.”
Ajaan Lee Dhammadharo)
This is looking sweet
How can I get a credit card with my BLF name on it?
Photoshop, or change your name
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make sure the TIR does not get damaged by the UV
[Reviews] Miboxer C4-12, C2-4k+6k, C2, C4 / Astrolux K1, MF01, MF02, S42, K01, TI3A / BLF Q8 / Kalrus G35, XT11GT / Nitefox UT20 / Niwalker BK-FA30S / Sofirn SF36, SP35 / Imalent DM21TW / Wuben I333 / Ravemen PR1200 / CL06 lantern / Xanes headlamp
[Mods] Skilhunt H03 short / Klarus XT11GT, XT12GTS / Zebralight SC50+ / Imalent DM21TW / colorful anodisation
[Sale]
Drivers: overview of sizes and types
DD+AMC based drivers Anduril or Bistro OTSM 12-24mm, S42, 24-30mm L6, Q8, MF01(S), MT03, TN42
Anduril or Bistro 8A buck driver for 20-30mm, MF01/02/04, TN40/42, Lumintop GT, MT09R
UVC and UVC+UVA drivers
programming key
Remote switch tail DD board with FET
Aux boards:
Emisar D1, D1S, D4, D4S, D18, Lumintop FW3A, Fireflies ROT66, Astrolux MF01, Tail boards like S2+
Interesting, what emitters did you have in there?
I was just planning on a low power 5mm UV emitter in the centre of the optic, probably 395nm or above as I noticed 365nm gets blocked by the plastic. I might also drill a centre hole in the optic but these decisions are made during the building.
- LEDs & Other Stuff - - UI CheatSheets - - CRX Flashlight Builds - - CRX Stuff for Sale -
I would definately go to a UV 365nm Emitter like Nichia 276A which needs no filter blocking visible light
Then you need to drill a hole
For that picture someone had hard driven 365nm and thought it were 395nm ones
Likely 1.5W UV radiance per emitter
[Reviews] Miboxer C4-12, C2-4k+6k, C2, C4 / Astrolux K1, MF01, MF02, S42, K01, TI3A / BLF Q8 / Kalrus G35, XT11GT / Nitefox UT20 / Niwalker BK-FA30S / Sofirn SF36, SP35 / Imalent DM21TW / Wuben I333 / Ravemen PR1200 / CL06 lantern / Xanes headlamp
[Mods] Skilhunt H03 short / Klarus XT11GT, XT12GTS / Zebralight SC50+ / Imalent DM21TW / colorful anodisation
[Sale]
Drivers: overview of sizes and types
DD+AMC based drivers Anduril or Bistro OTSM 12-24mm, S42, 24-30mm L6, Q8, MF01(S), MT03, TN42
Anduril or Bistro 8A buck driver for 20-30mm, MF01/02/04, TN40/42, Lumintop GT, MT09R
UVC and UVC+UVA drivers
programming key
Remote switch tail DD board with FET
Aux boards:
Emisar D1, D1S, D4, D4S, D18, Lumintop FW3A, Fireflies ROT66, Astrolux MF01, Tail boards like S2+
A nice wee delivery today means I can get started, a slab of copper, the rosewood and some bit's n' pieces.
The Dalbergia latifolia has a purple hue to it which is interesting, goes well with the copper I thought.
This piece is cut into a blank shape for making ukeulele/ mandolin fingerboards.
Hard as rock and sounds great too
Today's Tune:
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DELIVERY!!
..Sorry – that’s what we yell out at work whenever the postman arrives…
I refrained from shouting but I did smile and run to the door like an excited kid when I heard heavy stuff hitting the floor
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That’s plenty of rosewood and copper to do more than one of these…
The Cycle of Goodness: “No one prospers without rendering benefit to others”
- The YKK Philosophy
Looks a lot like the Eye of Sekhmet flashlight from Silent Thunder Ordnance, but smaller!
https://www.silentthunderordnance.com/shop/eye-of-sekhmet
Shame Carclo doesn’t make a 40mm catadioptric optic.
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What’s wrong with the 60mm one? I’m sure with your skills, you could find a way to “fit” it to whatever you were going to use the 40mm one for. Maybe a nice “setting” like jewelers do with diamonds?
The Cycle of Goodness: “No one prospers without rendering benefit to others”
- The YKK Philosophy
I really want this light to be as compact as possible, a 40mm version would have been perfect and I don’t think filing these things down is an option
Maybe could use it for a future build.
The wood I ordered is only 55mm wide but still, I’ll give it some thought
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- LEDs & Other Stuff - - UI CheatSheets - - CRX Flashlight Builds - - CRX Stuff for Sale -
Got the copper sheet cut into the rough shapes today.
I marked out the lines to cut with digital calipers, a set square and a #26 scalpel blade. I was not looking forward to cutting the metal with a hacksaw so I thought I would try just scoring it repeatedly with a stanley knife, about 20 times down the marked lines each side and then gently bending at the weakened points until the pieces snapped off, much easier
Each layer is about 1mm larger all round than required, to be made good and sanded down later.
Reference drawing
I also marked out where the glass, optic and MCPCB will be situated through the front piece using the digital calipers with one point held in the centre marking and the other point used to scribe the circles around.
These circles will help to keep me right when taking out this material with a hand file.
I will cut the rosewood next.
Today's Tune:
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I love copper. How thick?
BLF Member Map, add yourself
My 7th Annual contest entry My 6th Annual contest entry My 5th Annual contest entry My 4th Annual contest entry
My DBSAR inspired SRK lantern hand made mod
It’s 1.2mm thick, nice stuff.
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Measured and cut the wood, now got the rough pieces made up.
Reference drawing
Looks nice but you don't want to eat this sandwich
Today's Tune:
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