Jerommel's Hand Job 2018 - 6th annual BLF / Old Lumen Scratch Made Light Contest

75 posts / 0 new
Last post
MRsDNF
MRsDNF's picture
Offline
Last seen: 1 month 1 week ago
Joined: 12/22/2011 - 21:18
Posts: 13473
Location: A light beam away from the missus in the land of Aus.

Wow. This looks real interesting. Good on ya for entering. Beer

 

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.

 

Jerommel
Jerommel's picture
Offline
Last seen: 1 year 4 months ago
Joined: 01/04/2014 - 13:18
Posts: 6380
Location: the Hague, Netherlands

Progress has been slow, and i planned on getting to a working light today, but i have to wait for glue to dry now.

Pics and text:

I made a hole for the charging indicator lights.
Drilled a hole, put some Scotch ‘magic’ tape on the inside and filled the cavity with Kafuter UV curing glue.
The tape is frosted, acting as a diffuser.
Nice idea, but didn’t last…

I have an average to short micro USB plug in the charging port, and still some room to spare.

And then it was time to do some epoxy sculpting.

Switch button boxed in by epoxy, because i want to make this light as waterproof as possible.

A switch boot will fit over the button, shutting it off from water.

And also the USB port is surrounded by epoxy now.
The port itself is set in super glue and epoxy, so any water can’t really go through the port because all is sealed form the rear.

This was a bit dumb:

Had to make a new pair of holes for the LED board screws, in order to align the optics with the switch.
Why didn’t i think of that before?? Sick

Screws with rather large heads, but the right length.
Had to scrape some of the traces on the LED board out of the way to prevent causing short circuit.
Used a black marker to mask the mayhem..

Meanwhile, i ground some 1.5mm off the head length, also getting rid of the damages.

…needless to say, i dropped it AGAIN after that…
But after some cussing, hammering, squeezing and sanding it all ‘buffed out’ fairly nicely.

But this is the problem with this build…
The copper is actually too soft to make a light out of.
It would be okay if it was thicker, but it’s just 1 mm wall thickness..
So i’m looking for another tube, maybe aluminium, maybe brass, to slide over the light, to add some strength, particularly for the head.
But i’ll build it like this first, then we’ll see what we can find, or not..

Time to glue the assembly in place in the tube !

Kafuter is really handy stuff.
I put some in a syringe and filled the gaps between the epoxy and the copper.
Used a Singfire 324 with 395nm LED, shining around inside the cavity.

Also glued the battery in the tube the same way.

And the USB port.

It’s pretty strong stuff when cured.
And very thin so it creeps where ever it can.

So what about the Scotch tape?
Well, it damaged when i had to do some filing inside the tube after opening the USB hole a bit more to the right to get better alignment.
So in stead of the tape a put a bit of Kafuter there in stead, and made that surface frosted with a diamond powder coated file.
That was okay, although not as even as the tape..
But somehow either the Kafuter or some of the final addition of super glue got onto it, so it’s not entirely frosted anymore…
In fact, it looks quite messy now.. Tired
I think some particles got stuck in there too…
Too bad, but oh well..

So after pouring in some super glue, intended to creep between battery and copper tube, i added some more epoxy between driver and shelf, all just to make sure the insides aren’t going anywhere.

So now it hangs in my bathing room against the air intake, in order to suck away the fumes of the drying super glue.
I’ll leave it hanging there to tomorrow afternoon.
After that, i can put in the LED board and optic.
If i don’t wait for the super glue to shed its fumes, it might well deposit a white haze on the optics, so i’m not taking the risk.

To be continued…

MtnDon
MtnDon's picture
Offline
Last seen: 6 hours 40 min ago
Joined: 08/27/2015 - 18:25
Posts: 3772
Location: Canuk in NM
Thumbs Up
MRsDNF
MRsDNF's picture
Offline
Last seen: 1 month 1 week ago
Joined: 12/22/2011 - 21:18
Posts: 13473
Location: A light beam away from the missus in the land of Aus.

What sort of epoxy glue did you use?

 

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.

 

Jerommel
Jerommel's picture
Offline
Last seen: 1 year 4 months ago
Joined: 01/04/2014 - 13:18
Posts: 6380
Location: the Hague, Netherlands

This one:

Jerommel
Jerommel's picture
Offline
Last seen: 1 year 4 months ago
Joined: 01/04/2014 - 13:18
Posts: 6380
Location: the Hague, Netherlands

^ Does not contain metal, by the way.

Update:

No pics, just some reporting on the disasters of building this light..

I dropped the damn thing AGAIN !!

Big dent in the head….

BUT, i managed to un-dent it AGAIN ! Thumbs Up Beer

And then i put in the triple LED board, and somehow (i suspect how it happened though…) i have a short circuit, probably in one of the LEDS.

I’ve had it for today… Tired

I did glue a switch boot over the button, or rather, over the cylinder in which the button sits.
That went quite well. Drying now, should be cured tomorrow.

To be continued……………

vwpieces
vwpieces's picture
Offline
Last seen: 1 week 3 days ago
Joined: 07/17/2016 - 19:49
Posts: 2181
Location: PA, USA

Persistence man… keep at it.
Will be a really nice light when done.
Great work so far.

FmC
FmC's picture
Offline
Last seen: 7 months 1 day ago
Joined: 03/31/2013 - 05:23
Posts: 2197
Location: Brisbane, AU

Good thing you didn’t entomb everything together before finding out it had a short… Oops

BlueSwordM
BlueSwordM's picture
Offline
Last seen: 1 week 3 days ago
Joined: 11/29/2017 - 12:34
Posts: 5607
Location: Canada

Yeah. Shorting to that thick copper wall would have been bad for the 18650. Like venting.

It wouldn’t be too much of a problem(except for electrolyte smoking+leaking), but since you have an enclosed cell, well, it’s like with lithium ion pouches, but worse.

My very own high current Beryllium Copper springs Gen 3:
http://budgetlightforum.com/node/67401
Liitokala Aliexpress Stores Battery Fraud: http://budgetlightforum.com/node/60547

DBSAR
DBSAR's picture
Offline
Last seen: 12 hours 2 min ago
Joined: 02/11/2013 - 23:28
Posts: 6367
Location: Newfoundland, Canada

Nice work! Smile

That Canadian flashlight guy & Lantern Guru -Den / DBSARlight

Jerommel
Jerommel's picture
Offline
Last seen: 1 year 4 months ago
Joined: 01/04/2014 - 13:18
Posts: 6380
Location: the Hague, Netherlands

FmC wrote:
Good thing you didn’t entomb everything together before finding out it had a short… Oops

The short was not in the entombed (lol) parts.
They just slided in the tube and are fine.
I think i cracked one of the LEDs on the LED board…
See, those thin KD triple are not flat, so i tried to flatten it a little when the LEDs were already soldered on it..
That was dumb, in hind sight.. Facepalm
The LED board is fixed with screws, so i could take it out again.
Jerommel
Jerommel's picture
Offline
Last seen: 1 year 4 months ago
Joined: 01/04/2014 - 13:18
Posts: 6380
Location: the Hague, Netherlands

BlueSwordM wrote:
Yeah. Shorting to that thick copper wall would have been bad for the 18650. Like venting.

It wouldn’t be too much of a problem(except for electrolyte smoking+leaking), but since you have an enclosed cell, well, it’s like with lithium ion pouches, but worse.

It’s not a short to the copper tube. Thumbs Up

Jerommel
Jerommel's picture
Offline
Last seen: 1 year 4 months ago
Joined: 01/04/2014 - 13:18
Posts: 6380
Location: the Hague, Netherlands

vwpieces wrote:
Persistence man… keep at it.
Will be a really nice light when done.
Great work so far.

A true glue feast, is what it is.. Big Smile
Of course i won’t give up.
Close to finishing a working light now.
Learned a lot too.
I should do this more often.

To be continued…

Flashy Mike
Flashy Mike's picture
Offline
Last seen: 6 days 9 hours ago
Joined: 01/14/2016 - 16:38
Posts: 1222
Location: Germany

Yeah, this thin KD triple boards are crap. I ordered a couple of them way back with 219C mounted since they were pretty cheap but after mounting one of them into a S2+and the first LED dying quickly I never used them again.

Jerommel
Jerommel's picture
Offline
Last seen: 1 year 4 months ago
Joined: 01/04/2014 - 13:18
Posts: 6380
Location: the Hague, Netherlands

Well, i should have flattened the board BEFORE i soldered the LEDs on to it, of course… Facepalm
So i can only blame myself for this.
I knew they are not flat..

pinkpanda3310
pinkpanda3310's picture
Offline
Last seen: 1 week 3 hours ago
Joined: 12/28/2013 - 08:45
Posts: 2966
Location: Perth

Kudos for your persistence. Also nice job lining up and cutting out a slot for the USB port Thumbs Up

  

Jerommel
Jerommel's picture
Offline
Last seen: 1 year 4 months ago
Joined: 01/04/2014 - 13:18
Posts: 6380
Location: the Hague, Netherlands

Well, it’s on hold at the moment..
There’s still that short in one of the LEDs (probably), so i finally put together my LED reflow device, consisting of the intestines of a thermostatic regulated soldering iron.
The heating element plus sensor (a ceramic rod with 4 wires coming out) i put in a large solid aluminium knob, so i would have a hot flat surface of about 40mm diameter.
And it worked! …for 15 minutes… Facepalm
No idea what went wrong, but i chucked the whole thing in the bin…
And then the fluorescent tube light in the shed went out for the last time with a puff of smoke..
So i’m now replacing it with LEDs but also putting a 4 position switch regulator in the power line for the air extraction fan, which has been waiting for installation for quite a while too…
Much more work than anticipated, as usual..
And still no proper reflow thingy, which is a bit of a must for solder flowing 3030 LEDs on a triple 3535 board…

I will soon resume working on the light though.

…to be continued…

DavidEF
DavidEF's picture
Offline
Last seen: 3 days 5 min ago
Joined: 06/05/2014 - 06:00
Posts: 7699
Location: Salisbury, North Carolina, USA

The element possibly burned out because it isn’t made for that kind of load (heating that whole knob). Or, maybe it was near failure anyway, and it just happened to give up while being used to reflow that time. Even if it was new, unused, it could have had poor tolerance or a manufacturing error. Still, a bum deal to have it go out, and the fluorescent tube as well. Tired I hope you get back on track soon.

The Cycle of Goodness: “No one prospers without rendering benefit to others”
- The YKK Philosophy

pinkpanda3310
pinkpanda3310's picture
Offline
Last seen: 1 week 3 hours ago
Joined: 12/28/2013 - 08:45
Posts: 2966
Location: Perth

Aah, the joys of a man cave. To get to this you have to move that. And to finish making this you need to finish making that so you can use it to make this.

Good luck mate.

  

Jerommel
Jerommel's picture
Offline
Last seen: 1 year 4 months ago
Joined: 01/04/2014 - 13:18
Posts: 6380
Location: the Hague, Netherlands

DavidEF wrote:
The element possibly burned out because it isn’t made for that kind of load (heating that whole knob). Or, maybe it was near failure anyway, and it just happened to give up while being used to reflow that time. Even if it was new, unused, it could have had poor tolerance or a manufacturing error. Still, a bum deal to have it go out, and the fluorescent tube as well. Tired I hope you get back on track soon.

I don’t think it was the heating coil.
I think the electronics decided to stop working.
There was a red LED on the PCB (which was originally in the handle of the soldering iron), and all seemwed fine, it heated up, it shut off and then a few times it went on and off, keeping the temperature stable, and then it went off for good…
It just died on me…
Managed to remove an XP-L from a LED board and that was all it ever did…

Oh well… Sh.. happens.

I have the LEDs placed and working just now.
2 strips of 15× 5730 LEDs running an easy 5 Watts (0.33 Watt per LED) using 3S 600mA mains drivers, on 40cm lengths of aluminium curtain rail.
LEDs are 3000K (specified as 2700K but it’s a bit cooler) 95CRI Osram Duris E5 (new old stock) from a German Ebay vendor.
Nice lights.
Could do with some diffusing covers though..
Not really work lights, but for that i have a headlamp. Smile
Nothing beats a good floody headlamp.

Funner
Offline
Last seen: 2 years 3 months ago
Joined: 01/17/2018 - 12:49
Posts: 277
Location: UNITED STATES OF AMERICA

Cool

FmC
FmC's picture
Offline
Last seen: 7 months 1 day ago
Joined: 03/31/2013 - 05:23
Posts: 2197
Location: Brisbane, AU

Several builds down to the wire this year for one reason or another – I hope you can get your build finished!

Jerommel
Jerommel's picture
Offline
Last seen: 1 year 4 months ago
Joined: 01/04/2014 - 13:18
Posts: 6380
Location: the Hague, Netherlands

….aaaaaaannnndd i’m out of the ‘race’….

EVERYTHING went wrong..

All 3 LEDs were broken due to bending LED board, so i put on 3 new ones.
Problem solved, right?
Nope…
Something else must have gone wrong too, because i suddenly had only 1 mode Direct drive.
Yes, that would be the – minus making a short with the body.
And then the + wire broke off when investigating.
So, i had to get my pipe cutter to cut of the head, but the because of the epoxy potting i tore off some parts of the driver.
Soldered them back, but it didn’t work anymore…

All would have been well if i didn’t have broken and short circuiting LEDs from bending the LED board flat with a tap with a hammer on a rod placed in the centre of the board earlier…
Facepalm Facepalm Facepalm
Now it’s all for nothing, or at least, for this contest / build off.
Crap, crap, crap…

MRsDNF
MRsDNF's picture
Offline
Last seen: 1 month 1 week ago
Joined: 12/22/2011 - 21:18
Posts: 13473
Location: A light beam away from the missus in the land of Aus.

I feel your frustration Jerommel. You showed us some amazing skills. Dont let it eat you up. Beer

 

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.

 

CRX
CRX's picture
Offline
Last seen: 5 months 1 day ago
Joined: 04/02/2013 - 15:27
Posts: 4231
Location: Scotland
Sad
djozz
djozz's picture
Offline
Last seen: 1 hour 21 min ago
Joined: 09/07/2012 - 17:04
Posts: 17961
Location: Amsterdam

Still well done Jerommel! I did not even dare to start with a scratch build, while you did start and even came up with some really cool concepts! Thumbs Up

Jerommel
Jerommel's picture
Offline
Last seen: 1 year 4 months ago
Joined: 01/04/2014 - 13:18
Posts: 6380
Location: the Hague, Netherlands

@MRsDNF:

Yeah..

I still can’t believe the + wire just broke off…
It broke off where the wire couldn’t even bend, 3 to 4 mm inside the epoxy… Tired

But oh well, it was very educational…
The battery with charger and switch in the tube still work, so i can put a new head on it eventually..
We’ll see..

Jerommel
Jerommel's picture
Offline
Last seen: 1 year 4 months ago
Joined: 01/04/2014 - 13:18
Posts: 6380
Location: the Hague, Netherlands

djozz wrote:
Still well done Jerommel! I did not even dare to start with a scratch build, while you did start and even came up with some really cool concepts! Thumbs Up

Thanks Djozz.
Better luck next time.
MascaratumB
MascaratumB's picture
Offline
Last seen: 13 hours 24 min ago
Joined: 10/29/2016 - 12:12
Posts: 6802
Location: Portugal

Hey, sorry to hear this Sad
I was liking the concept and work!

Don’t lay your arms down, pick were you stopped and restart, even if it is not for the contest Wink The time invested so far is much more than the one remaining to get a full working light Wink

CheapThrills
CheapThrills's picture
Offline
Last seen: 1 week 17 hours ago
Joined: 07/02/2011 - 10:45
Posts: 3650
Location: Suomi

Very oldskool, very cool 8)

Pages