[Review] 77 Outdoors D25 Headlamp (18650)

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alpg88
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this is my d25 mule.

if anyone needs spare reflectors i have 2.

alpg88
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gchart wrote:

I have a 3D printer as well and am pretty decent at design, but I just got rid of my D25 so I can’t measure dimensions.

in that case i have a business proposition for you, i’ll send you a brand new d25, i have one nib. (i got several, they make decent presents) would you be willing to make an stl, and post it here so anyone can download it, and print one if they need? make one with your name on it so everyone who prints knows who designed. brackets are identical for d10 d20 d25.

gchart
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I’d be up for that, but if you have calipers, how about we call that Plan B?

If you can, take a couple good pics of the holder and a few dimensions (tube diameter, distance between, ring opening gaps, finger thickness, etc). I could take a stab or two with that and if worse came to worse, then pass one along Smile

alpg88
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Excellent. i’ll send you a caliper too. i think this will benefit many on this forum.
Now there are 2 types of holders, older one was holding better, newer one is loose, its grips are thinner, base portion of the old one had double curve, newer one is single, which is perfectly fine, after heating grips with a heat gun, (got to be careful not to overheat or they start bubbling, still works thou) and bending them in tiny bit, they hold as good as old one, if not better than old one, i may still have 1 old holder somewhere, if i do i’ll post pics so you can see the difference. we’ll probably better off opening new thread for that, once you get my package. pm me where to send it, and i’ll drop it off in a few days.
i like this design a lot better than silicone holder of ZL, or skilhant, and others, you can pop the light out in half a second, and just as fast put it in. ideally i’d like to replace my zl, and h02 holders with these. but will talk about it more in dedicated thread.

gchart
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Woah, sorry… I meant if you have calipers, how about you just send me some measurements for now to see if we can get one created that way. I’ve got a decent set of calipers. I’m just looking for pics and dimensions Smile

alpg88
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I took all measurements, but not all are critical, as you see they made some parts thinner, and hollow, i guess to save on plastic, no need to do so in our case. also it is made of molded abs i assume, not sure if printed one will be just as strong, maybe some thin parts need to be thicker, idk.

alpg88
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oh and the radius of the bend, of the base is around 150mm, i compared it to a 1 foot diameter circle, curves match, but that isn’t critical dimension,

pc_light
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Maybe add a third loop/slit for optional over the top headbands? Smile

Seeking the light.

gchart
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So… care to print this out and check? I’m sure I messed something up along the way, but it should make a decent first draft.

Re: a third-strap model… absolutely. Just after we get a working copy of the two-strap version.

https://www.thingiverse.com/thing:4035064

alpg88
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wow, awesome. wish i had your skills, i will try to set up my printer tonight and test print it,

gchart
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Thanks man. I got my first 3D printer (an Ender 3 Pro) back in July and have only dabbled in design since first getting it. But I like testing my skills and having a go on something functional is good practice for me. BTW, this was made in Fusion 360. Let me know how it goes!

alpg88
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It works!!! almost perfect, fits just right, sits firmly.

set up my cr10s last night that has been sitting for more than a year, and realized , i reinstalled windows, so my slicer is gone, installed cura 4.4, and realized i forgot pretty much everything, took me a while to figure basic settings, still did not figure most of them, thus you see stringing.

i used petg. to be honest that particular petg from e sun was always stringy before, but in any case holder works awesome, one thing thou, that tooth, that supposed work as a stop is too low, but grips hold the light so firm, it really is not necessary, but it was a bit longer, of entire light was deeper in, it would work, i guesstimate 1-1.5mm would be enough.(if too long it could always be filed down a bit) that is about the only change that could be done. i assume if printed from abs i’d need to adjust the scale in a slicer to compensate for shrinkage, like 0.5%?
,
in any case awesome job, THANK YOU. now pm me where to send that brand new d25, as i promised.

gchart
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Woah, I can’t believe I got that close on my first try. Great job on those measurements! PETG should hold up ok with the heat, and hopefully should be pretty strong… I don’t have any PETG yet but I’m hoping to get a roll or two for Christmas.

I think I’ll bring the “rings” backwards ~1.25 mm (bringing the headlamp back towards the arc). Also, it looks like perhaps the rings could be moved apart about 0.5mm each? While I’m in there, any other minor tweaks you can think of?

I really do appreciate the offer, but I’ll pass. I just shipped my D25 to a BLF member for a song, and I’ve got a nice TH20 and a few Convoy H1’s. To make use of any more headlamps, I’d need to turn into Medusa Wink

alpg88
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you could move the rings apart too. seems like there is about .5mm room there, aa far as other tweaks, not really, maybe another version with wider base, for 35mm rubber band. if you feel like it, but otherwise this one is pretty much as good as it gets

i’m not sure i want to bother with abs, seeing how this one came out pretty good, petg supposed to be as strong and as heat resistant as abs, originally i wanted abs, but for first try i figured i do petg not to mes with acetone and stuff, but now i think i’ll abandon abs idea, maybe will get different petg, i heard esun isn’t the best brand out there.

gchart
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Update (new files are at Thingiverse):

  • Grips/rings moved 1.25mm rearwards (closer to the arc)
  • Grips/rings moved 0.25mm further off center (so now a total of 38.5mm between them)
  • A 3-strap version added

PS – do you mind if I add this picture to the Thingiverse posting so that people can get a real-world visual?

alpg88
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don’t mind at all, use it anywhere you want, it is your design

Tom E
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Wow, great job all! Now who can make a copper dual MCPCB? I'm in for at least two! smile

alpg88
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i wonder it we can just use 2 16mm stars, reflectors will align and center them, it looks like they may just fit, but the reflectors aren’t that good, the beam is a donut, led is not in focus. i wonder if xp leds would focus better

gchart
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I don’t have measurements on the MCPCB, but I have written down that the reflectors have a 15.9mm diameter, so it stands to reason that a 16mm MCPCB would fit. You could try two side-by-side, or if you want to go mule-style, just use some thermal adhesive and mount a single one in the middle with a clear window over top.

Tom E
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Possible. I'm using one of these on the bench running NarsilM - work'n pretty good. Like the ramping for a HL.

Here's a library of pics of the mod: Dual LED headlamp album

 

pc_light
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I use my 219B reflowed D10 with gChart RampingIOS and lit tailcap quite often, indoors now.

With a new optional strap I might get to use it more often outdoors as well.

gchart wrote:
Update (new files are at Thingiverse):
  • Grips/rings moved 1.25mm rearwards (closer to the arc)
  • Grips/rings moved 0.25mm further off center (so now a total of 38.5mm between them)
  • A 3-strap version added

!{width:400px}http://www.ghart.com/blf/misc_pics/d25_clip_3strap.jpg!

Seeking the light.

alpg88
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version 2 is a success, stop connects with the light body just like it does on oem holder. awesome work, thanks again gchart.

gchart
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Awesome, thanks for confirming!

Quadrupel
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Now D10-D20-25 have Fet+7135 driver and can run Anduril and Zebra like UI for 10 $
cameringo-20191213-174736

gchart
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Very cool!

alpg88
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Quadrupel wrote:
Now D10-D20-25 have Fet+7135 driver and can run Anduril and Zebra like UI for 10 $ cameringo-20191213-174736

wow, this is very coll, i’d get several. where can i get them?

alpg88
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printed one more, purple this time, love them. i use 35-40mm band, they are not adjustable, i do not need it, but even when i close them based on my head circumference, pretty much any adult can wear them with no issue, even 9 years old kid was wearing one and it was not loose, i like wider bands, they grip better, they do not need to be as tight, and they come in many cool designs, . they also eliminate the need for top strap. imo.
i used 0,2 layer this time, it saved 3 hours on printing, and unless you are really looking up close, they don’t look any different. i took me half a dozen of fails before i diled right settings with esun petg, now it seems to be printing pretty good

if you ever feel like it, and have time could you make the base wider for 35mm band, just the base , grips are fine the way they are. now it has folds under the base plate, which isn’t really a big deal, but it would be more comfortable without them, again if you ever have time and feel like it, imo wider band really improves the experience. with your holder\wider band, and new driver this cheap light is really turning into a very good one.

one thing, you got to print them on the side, if you print them flat, grips snap as soon as you try to put a light the first time, but with layers running along the grips, they flex just fine. side printing requires supports, that leave bad finish, but they are only inside the grips so you do not see it when the light is in.

p.s. feel free to use these pics if you want to upload them to thingiverse, or anywhere else

Wieselflinkpro
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Quadrupel wrote:
Now D10-D20-25 have Fet+7135 driver and can run Anduril and Zebra like UI for 10 $
cameringo-20191213-174736

I need one or two.
Is it possible to use the original charging board with this driver?
Quadrupel
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Yes, you can charge it as usually. Sorry, I had only 4 drivers , all gone for now, but in week or 2 i will get parts so assemble much more

Boaz
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  There are two different versions of the plastic holders . the one I got from Sofirn's D25 had a hole and a flexing tab with a nub ... where the original had just the nub . The older version with just nub is much better ,hold the light in much better ,works much better . The one with the hole doesn't hold the light worth a damn and the light falls out way too easily .

  I've ordered multiples of this headlamp off ali and ebay .It's definitely a favorite of mine .Glad to see some modders doing cool mods on this true budget light .

       καὶ τὸ φῶς ἐν τῇ σκοτίᾳ φαίνει καὶ ἡ σκοτία αὐτὸ οὐ κατέλαβεν

                            

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