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

Hi all,

2nd time i entry this yearly contest.
Main goal: Finishing a working light. :partying_face:
Previous attempt (2014) kind of failed due to running out of time, so i thought i’d keep it straight and simple.
So here are the parts:

It’s gonna be a copper 20700 triple with Osram Oslon Square high CRI warm white with a lovely tint and a bunch of real red.
These LEDs are no power houses, so i’ll run them on 1 Ampere each, using a 3 Ampere FET CC driver.
It will be USB rechargeable too.
I’ll use Kaidomain LED board and optics.
Little Omten reverse clicky side switch.
Basically the light wil be built on / around the 20700 battery, which will not be removable.
…at least, not easily…
Trying to make it as compact as possible.

You gotta be careful with those Handy J's...

You don't want to end up like CRX:

So i started this afternoon, it is now 3:28 AM here…

Pictures!

Without the wrapper it nearly slides in the tube, if both were perfectly round, which they’re not…

The Osrams are 3030 LEDs, which had to be reflowed onto the triple 3535 board.

Took some time, effort and cusses to get them all positioned decent enough.

Need a shelf for the LED board to sit on inside the tube.

20 x 20 x 1.5 mm heat spreader to make the shelf.

Must be soldered in place.

Needs holes for wires and 2 tiny screws.

Can you see the damage on the business end of the tube?
I dropped it on the concrete floor… :person_facepalming:
I’ll address it later. Maybe need some extra ring around there to make it a little more impact resistant…

Time to do the electrical bits.

These charger boards are quite okay.
I won’t need the protection circuit though.

battery connections.

Cut down board goes on top.

Epoxied, soldered, works !

Switch gets glued to bottom of driver.

And that gets glued on top of the charger board.

Tested and working. :+1:

More epoxy for strength.

CONTINUED HERE

Well, you did say it would be compact… :open_mouth:

Looks good mate!

Why take the wrapper of? why not just use a 18650?

Great start :star: looking good :+1:

Interesting!

Well, i bought 2 of those 20700’s almost a year ago now, but i haven’t got anything to use them in…
And then i found that, with a little persuasion, it can fit inside a 22mm diameter copper pipe when you remove the wrapper.
Triple board and optic also fit snugly in this size tube.

Great start to your build :+1:

I have a couple of those charging circuits for my build - Interesting to see how you cut them down like that.

Cool :+1:

Looks interesting! Pretty compact indeed.

Nice :wink:

Very nice with a couple of cool new concepts! :+1: :+1:

Thanks for the encouraging comments!

I could have used the Convoy S9 e-switch driver with USB charging port, but i didn’t like the idea of parasitic drain, so i used a reverse clicky set up in stead.
This takes up more space though, and it will be a bit more of a challenge to sort out the switch button.

And that will be the next part of the build:
Holes for the USB port, charging LED light and switch button.
Also have to widen the copper tube a tad to get the assembly in without too much force.
Lining the lot up properly will be a bit of a challenge too…

Very cool, very nice, Jerommel. :+1:

Looking great, Jerommel! Very cool setup so far, I like how you’ve got everything stacked tight and epoxied in place (JB Weld?). Interesting how you’ve trimmed down the charging circuit. Are the eliminated bits just for over/under voltage protection?

The battery does not have its vent holes anymore btw, whatever the implication is of that.

Pipe Bomb! :smiling_imp:

Yeah, maybe i’ll send it to some globalists… :smiley: :partying_face:

But it’s true, it’s gonna have a harder time venting.
I decided it was not that important.

Nice work Jeroen. Looking forward seeing the end result.