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

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YuvalS
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Today I made the helmet mount from a 1.5 mm aluminum:

After cutting it to proper dimensions, I had to curve it so it will sit properly on the helmet:
  

Luckily a 18650 cell came out very handy to draw the 2 half circles at the ends:


To fold it precisely, I made small cuts at two sides of the Aluminum:
 

Unfortunately, I forgot about the cable gland when designing this mount so I had to file it a bit in order to allow a better pitching range Sad 


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My BLF/OL contest entries: 7th 8th 9th 

MRsDNF
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Lots of members here have posted up there caving pictures. Personally I find them fascinating.

Your light is coming along nicely. What thread did your gland have? After a couple of small ones myself.

 

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.

 

YuvalS
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MRsDNF wrote:
What thread did your gland have? After a couple of small ones myself.


This gland is shitty chinese one with no standard thread.
If you need small one I recommend the mini Lapp Kabel, Ip68 with standard metric thread. 
I have used the M8 one for previous project and it is perfect for 2*0.75^2 cable. 
https://www.ebay.com/itm/LAPP-KABEL-52001880-CABLE-GLAND-MINI-M8/171859331326?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2057872.m2749.l2649

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My BLF/OL contest entries: 7th 8th 9th 

MRsDNF
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Thanks for the link YuvalS. I did not think to look on Flea Bay. 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.

 

YuvalS
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While waiting to get the electronics I ordered from Fasttech (I am getting a bit worried that I won't get it in time to finish the light till the end of the month surprised)  I decided to build the battery case:

I first saw the body from a thick cutting board, making a tight space for a double 18650 battery holder:


Then drilled holes for the screws and cable and file the battery holder to make some space for the wires: 


I cut the rear and front covers from 2 mm Perspex:


And had to sand it:


After a lot of sanding:


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My BLF/OL contest entries: 7th 8th 9th 

MtnDon
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Thumbs Up Sanding can be a drag; sometimes it seems to take forever. Looking good. I hope you get the parts needed soon.
MRsDNF
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Thumbs Up

 

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.

 

YuvalS
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Continuing with the battery box, today I soldered and glued the cable

First I wanted to easily identify the right polarity for the batteries even while changing batteries in the cave using the spare light:
   

So I painted half of the battery holder in red to mark the positive side Smile 


Then I soldered the cable (2P1S):
   

And last thing for today, glue the cable and seal the hole:


I had to glue it instead of using a cable gland since the hole is very close to the edge in order to allow the wires to enter the case below the battery holder.
I used shoe goo because is is perfect for this purpose: bond good to plastics, elastic and waterproof cool
Now I have to wait for the glue to cure... 

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My BLF/OL contest entries: 7th 8th 9th 

MRsDNF
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The holders are looking good. Thumbs Up

 

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.

 

YuvalS
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Today was waterproofing day....

I cut rubber seals for the battery box: 

 

And for th head unit:


And glued everything 


So again I have to wait for it to cure....

The next step (unless I finally get the electronics package) Is my patent how to secure the screws so I don't lose them while changing batteries, not sure if I can explain it in pictures maybe I shoot a short video   

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My BLF/OL contest entries: 7th 8th 9th 

MtnDon
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Always nice to see your progress.

MRsDNF
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I see you have a long weight. Facepalm

 

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.

 

DB Custom
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We call that a BFH Steve. For those times when the LFH just won’t get it done…. Wink

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MRsDNF wrote:
I see you have a long weight. :FACEPALM:


DB Custom wrote:
We call that a BFH Steve. For those times when the LFH just won't get it done.... ;)


Hammer is very important tool for caving (less important than light, butt still...) carrying one out of couple hundreds meters dip cave is a doubtful pleasure.

Today I finally started working on the FW.
I used the opportunity to build a third (and fourth) hand after the parts were lying on my desk for months:

 

Then I solder an Arduino shield with 2 LEDs and a momentary switch to help me develop my costum caving FW for 2 separate emitters:

 

As usual, programing the Attiny using Arduino was pain in the A** but finally I managed to burn the "blinking" test program    

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My BLF/OL contest entries: 7th 8th 9th 

MRsDNF
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With all that black magic going on I’d lock those helping hands up at night just to be sure. Silly

 

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.

 

YuvalS
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Although I already made my own helmet mount, I decided to change it and go for the common GoPro mount.

I bought an aluminium mount but had to modify it in order to fit headlamp instead a camera and also to shorten it in order to keep the light closer to the helmet 
 

 

Then I had to cut part of the heatsink in order to make space for the mount as close as possible to the body
  

And the final result 


Now I have to drill in my helmet, not sure I am ready for this irreversible step surprised

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My BLF/OL contest entries: 7th 8th 9th 

MtnDon
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YuvalS
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MtnDon wrote:
3M doublestick tape....VHB https://www.3m.com/3M/en_US/vhb-tapes-us/[/quote]
Is it strong enough? I tend to hit my head in rocks while caving (hence the helmet) 

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My BLF/OL contest entries: 7th 8th 9th 

MtnDon
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There are several varieties. I do not know all there is to know about which one for what job. BUT, the VHB tape is used to hold the aluminum metal panels to the welded steel or wood framework of some cargo trailers. Many trailers use screws to secure the panels, but there are some that have no exterior screws showing. Those are VHB taped. I have used VHB for small projects and it has worked extremely well.

https://www.tecmanuk.com/news/posts/applications-of-3m-vhb-tapes/

I would have used it to affix the wood skins to my contest entry, but the only tapes I have on hand are too thick. But probably ideal for a helmet light.

have used this one on many things.

https://smile.amazon.com/gp/product/B01BT0A6MG/ref=ppx_yo_dt_b_search_as...

Check out this article

MRsDNF
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Nice idea for a mount YuvalS. What did you use to cut the heatsink fins out to fit the mount?

 

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.

 

YuvalS
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MtnDon wrote:
There are several varieties. I do not know all there is to know about which one for what job. BUT, the VHB tape is used to hold the aluminum metal panels to the welded steel or wood framework of some cargo trailers. Many trailers use screws to secure the panels, but there are some that have no exterior screws showing. Those are VHB taped. I have used VHB for small projects and it has worked extremely well. https://www.tecmanuk.com/news/posts/applications-of-3m-vhb-tapes/ I would have used it to affix the wood skins to my contest entry, but the only tapes I have on hand are too thick. But probably ideal for a helmet light. have used this one on many things. https://smile.amazon.com/gp/product/B01BT0A6MG/ref=ppx_yo_dt_b_search_as... "Check out this article":https://www.fastenation.com/blog/an-experts-guide-to-using-3mtm-vhbtm-ta...

 

Thanks, I will check it

 

MRsDNF wrote:
Nice idea for a mount YuvalS. What did you use to cut the heatsink fins out to fit the mount?

 

I took this idea from some commercial lights.

Cutting the heatsink was challenging, I used most of my Dremel bits the most helpful was the engraver

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My BLF/OL contest entries: 7th 8th 9th 

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If you do end up using double sided tape, I recommend using a mount with the largest possible area for the tape. It will be much more durable.

  

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Logo’s are attached to car bodies with similar tape, typically 3M. VERY difficult to remove once pressure-set in place. An absolutely clean surface is required of course for the adhesive to stick at full strength.

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I think the stuff you guys are on about is acrylic adhesive tape. 3m make the original stuff, though you can buy it anywhere. As DB says, once that stuff gets hold of the right surface, it’s not coming off in any hurry – on the wrong surface it will fall off just as easily lol! It loves plastics, but not oily types ( I don’t mean covered in oil)
This is the stuff , but you can get it on double sided foam too.

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I think I will use a glue, so isn't regular (paste) glue will be better than double sided?

In addition, manufacturer recommend not using any glue nor stickers on the helmet, what do you think? Can it weakens the helmet?

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My BLF/OL contest entries: 7th 8th 9th 

YuvalS
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It is time to start working on the circuit, I had an Idea to try print the PCB at home but most of the components are still on the way from China frown
Luckily I did got some drivers for other project and can use them:

  1. In order to separately control 2 LEDs (Flood and Spot) I have to use both PWM pins of the MCU. (pin 5 and pin 6).
  2. Pin 2 (PB3) will be set as a pull up input and be connected to GND by a Momentary NO switch.
  3. Pin 3 (PB4) will be set as a digital output and connected to a blue (red is in the lost package) LED for battery indication.

Since I have to use a Nanjg 105C and a 1.4A single mode Drives, the control of the 2nd driver will be connected to Star2 (pin5 - OC0A) of the Nanjg.

The blue led will be connected to Star3 (pin3 - PB4)

And the switch to Star4 (pin2 - PB3)

 

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My BLF/OL contest entries: 7th 8th 9th 

MRsDNF
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H’mmm. Someone else to be scared of. Didn’t know you were into black magic. Silly

 

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.

 

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Startin soldering, first I had to add 4 more AMCs to the 1.4A driver in order to allow maximum output of 1000 Lumens for each LED
 

 

Unfortunately it wasn't the tiniest thing I has to soldar, but first I cut the outer GND ring of the Nanjg 105C to allow easier and stronger soldering to the stars:
 

Finally I soldered 1806 resistor and LED to star3:


This is the first time I am soldering SMT parts by hand and it wasn't fun. 
Next step is optics.....

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My BLF/OL contest entries: 7th 8th 9th 

MtnDon
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YuvalS wrote:
This is the first time I am soldering SMT parts by hand and it wasn’t fun.

Yessir. Those are difficult to work with. You have a certain amount of bravery to venture into that

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MtnDon wrote:
YuvalS wrote:
This is the first time I am soldering SMT parts by hand and it wasn’t fun.

Yessir. Those are difficult to work with. You have a certain amount of bravery to venture into that


Have to agree with Don here. Nice effort. Thumbs Up

 

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.

 

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