YuvalS's Hand Made Class, 7th Annual BLF/OL contest entry topic

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Wed, 11/20/2019 - 07:55

YuvalS

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YuvalS's Hand Made Class, 7th Annual BLF/OL contest entry topic

So I am planning on building a headlamp, hopefully I will finish it by February.

The body will be made of aluminum to double as heat-sink and the battery box will be made of some kind of plastic. both will be build using hand tools.

I want to print my own driver but I have no experience with printing circuits so maybe I will use a commercial driver and modify it.

As a FW I am planing to use my own code that is need some improvements.

Welcome to share your thoughts.
Yuval

EDIT: 29/02/2020
Just before the deadline, I wanted to thanks all BLF members that helped and encouraged me during the build and especially to the annual BLF/OL contest team that pushed me to build the light
I made a short video to summarize the process so people don't have to read the entire thread:

And here is pictures of the final result:

Evanualy, I did used some modified commercial driver and didn't print my own, maybe for the next year competition....

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My hand Made Class, 7th Annual BLF/OL contest entry

My modification Class, 8th Annual BLF/OL contest entry

Edited by: YuvalS on 02/29/2020 - 08:30

Wed, 11/20/2019 - 07:56

sb56637

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Sweet! Really looking forward to it.

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Wed, 11/20/2019 - 09:42

CRX

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Sounds good, always nice to see a self built headlamp

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Wed, 11/20/2019 - 14:37

MRsDNF

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All the best for the build YuvalS.

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Fri, 11/22/2019 - 18:45

YuvalS

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MRsDNF wrote:
All the best for the build YuvalS. :THUMBS-UP:

Thanks MRsDN, you too.

So today I made the preliminary sketch of the body.
I am planing to built it using 3 pieces of 6mm Aluminum glued together.
6mm Aluminum is easier to buy and easier to work with using the tools I have.
3*6mm = 18mm will give me enough space for a 17mm driver and 14mm optics + 2 mm mpcp (=16 mm)

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My hand Made Class, 7th Annual BLF/OL contest entry

My modification Class, 8th Annual BLF/OL contest entry

Fri, 11/22/2019 - 19:53

pinkpanda3310

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Nice start

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Wed, 11/27/2019 - 03:35

DBSAR

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subscribed!

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Wed, 11/27/2019 - 04:33

G0OSE

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Subscribed!

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Sat, 11/30/2019 - 13:24

YuvalS

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So my GF travel to Germany for the weekend and I had an opportunity to take over the living room and convert it into a workshop

I started to build the body. Since it it made out of 3 pieces of aluminum I decide to first attach the 3 pieces together using screws. It will enable me to precisely drill the 2 mm drills for the screws around body.
I did not manage to use the drill press before the pieces are screwed together so I had to drill another set of drills by hand

I tapped M4 to the bottom aluminum piece

And now I screwed all pieces together and can continue working on body but I have to wait for the next time I will be able to conquer the living room

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My hand Made Class, 7th Annual BLF/OL contest entry

My modification Class, 8th Annual BLF/OL contest entry

Sat, 11/30/2019 - 14:18

#10

grin

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Good stuff. You may find it easier to tap the holes with a battery drill, it is easier to keep the tap straight. Use WD40 or something similar to lubricate it.

Sun, 12/01/2019 - 01:57

#11

YuvalS

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grin wrote:
Good stuff. You may find it easier to tap the holes with a battery drill, it is easier to keep the tap straight. Use WD40 or something similar to lubricate it.

I have lubricant in this green plastic. I also use it for drullind and sawing but never thought of using a WD40, maight be easier to apply, THX

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My hand Made Class, 7th Annual BLF/OL contest entry

My modification Class, 8th Annual BLF/OL contest entry

Sun, 12/01/2019 - 03:11

#12

MRsDNF

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You are in so much trouble when your GF reads this thread YuvalS. Love your style.

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djozz quotes, "it came with chinese lettering that is chinese to me".

"My man mousehole needs one too"

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Sun, 12/01/2019 - 07:00

#13

CNCman

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YuvalS Nice build. subscribed

Note: If you do not want oil on your projects, dish soap works just fine.

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Sun, 12/01/2019 - 08:42

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CRX

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Good start

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Sun, 12/01/2019 - 20:21

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pinkpanda3310

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Nice room conversion Good to see you make a start

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Mon, 12/02/2019 - 00:02

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MtnDon

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Mon, 12/02/2019 - 06:05

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YuvalS

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After the progress yesterday I wanted to continue working on the body after work. Unfortunately my neighbors are not big fans of me building lights at night (TBH they are also not like it when I build other stuff)

luckily, I have found a 220v outlet next to the road around my neighborhood, far from any building and was able to work there

As you can see I have took CNCman advice about using dish soap as a lubricant since it is easier to use when working outdoors

It was quit challenging to drill 12 2mm holes in a 5mm border but I am quite happy with the result, no drill pierced the side of the body and I only broken one drill bit

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My hand Made Class, 7th Annual BLF/OL contest entry

My modification Class, 8th Annual BLF/OL contest entry

Mon, 12/02/2019 - 07:40

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Kame Sennin

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YuvalS wrote:

luckily, I have found a 220v outlet next to the road around my neighborhood, far from any building and was able to work there

Perfect combo of will and "do with what you have" spirit !

Mon, 12/02/2019 - 07:37

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CRX

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YuvalS wrote:
After the progress yesterday I wanted to continue working on the body after work. Unfortunately my neighbors are not big fans of me building lights at night (TBH they are also not like it when I build other stuff)
luckily, I have found a 220v outlet next to the road around my neighborhood, far from any building and was able to work there

That’s dedication.

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Mon, 12/02/2019 - 08:14

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pinkpanda3310

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What they said ^

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Thu, 12/05/2019 - 13:06

#21

YuvalS

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Today I sawed the corners and turned the rectangle octagonal.
Unfortunately I forgot the jigsaw blade at home and the Dremel blade is too small, so I had to use a hand saw.

After sawing, I smoothed it all out using a file. The result is not perfect, but since it all done using only manual tools I am quite satisfied.

The body is finally take shape

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My hand Made Class, 7th Annual BLF/OL contest entry

My modification Class, 8th Annual BLF/OL contest entry

Thu, 12/05/2019 - 13:32

#22

CRX

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You’re crazy mate
Couldn’t tell where you were this time

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Thu, 12/05/2019 - 14:23

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MtnDon

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Looks like good work under less than ideal conditions.

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Thu, 12/05/2019 - 14:34

#24

MRsDNF

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Love the new workshop.

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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.

Thu, 12/05/2019 - 16:40

#25

YuvalS

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Thanks guys, it is the same workshop as previous pictures .
Looks like I will not change this place unless someone will kik me from there.
I am also using this spot to work on my camper car conversion so it is a busy workshop