CNCman's entry to the 7th annual BLF/O-L contest [mod light category]( FINISHED )

What an honor it is to compete with you guys here at BLF. I wanted to compete last yr but was unprepared.
I’m kinda going out on a limb here entering this contest this yr because I have nothing to work with yet.

Last week I ordered Santa a Haikelite MT09R 3x XHP70.2 from Banggood using Fin17 discount code for $109.32.
It will be shipped 12122019, so maybe early 2020 it will arrive.
After ordering, I remembered there were driver problems looming over this light. So after researching on BLF, it was clear cheap MOFFSET on TA design driver. So in hope of salvaging this light, I contacted Lexel and he still had one, so it is ordered.

So basically this mod will be a driver upgrade and spring bypass and any suggestions from you guys.

Note: Haikelite suppliers were shipping subpar MOFFSET and TA was in no way approving this.

Great to have you enter CNCman. Good luck with your entry :beer:

Sounds nice! Good luck with your build.

I assume you have ordered in the color temperature you like. Otherwise you could swap the leds as well.

If you want you could have a look under the MCPCB if there is enough thermal paste. I have got a Q30 where not the whole copper surface was covered with thermal paste, just a small part in the middle. The copper based thermal paste Haikelite uses should be good.

Its good to see you enter the world of fun CNCman. :beer:

Aside from the venerable FET, MT09R is an excellent light, there’s not much you can do to improve performance.
If you’re after small gains:

  • I don’t recall if MT09R has bypassed springs. If no, you could do that
  • use as fat lead wires as you can

If you have a steady hand you may try to slice and dice the emitters. This will be a big improvement in throw at the cost of some 10–20 lumen loss. Personally I really like sliced and diced LED mods, I feel they are well worth the effort and I haven’t seen one in MT09R yet. :slight_smile:

You may do some visual mods if you like as well. :slight_smile:

Great to see you are entering the competition :beer: and am looking forward to seeing your mods!

Welcome to the fray! :wink: :+1:

Great to see you entering the contest CNCman. :+1:

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I may need to change to a different mod because the Haikelite MT09R I ordered has not been restocked and will not be shipped until next year.
Banggood said it would be shipped two weeks ago and when they changed the order page to ” Do you want another item at similar value “, I requested a refund. After chatting with Banggood again , they said it was now in stock, so gullible me reordered it again. Now it says its ” Out of stock ” again. So I will let it go again for a few weeks and see if the MT09R will ever be restocked.

Meanwhile back at the ranch…. I was able to squeeze in some time to make some parts for a MT07 Buffalo. If I can get the heatsink made tomorrow, that should be the last part for now. All the parts were made after the beginning of the competition. If its OK, can I switch to this Mod ?

Sure :+1:

OK :+1:
GREAT :+1:
I am getting some pics ready.

Buffalo host has a lot of potential as well. I have MT07S but I consider MT07 host to be much better. :slight_smile:

OK, It’s on now. Sorry for the confusion getting started. I purchased this Haikelite MT07 just after joining BLF. This is my first big led light and I was inspired by you guys to buy it. This was an early version with the old XHP70 led and OP reflector. I really liked it at first, but after learning more, it was time to try to make it better. I ordered a SMO reflector just one month after buying the light. Just a few weeks ago, work slowdown has finally allowed opportunity to access machine time after work hours. After drawing this up on FREE 2D CAD from Seimens PLM, it was verified it will fit and do-able.
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Guess I wanted a thrower and didn’t care for the OP reflector.
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The FREE 2D CAD from Seimens PLM is easy to learn and use, best 2D I found.
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The new and larger reflector needed to be measured all over for dimensions for clearance fits. Threads were 1mm pitch.
This process of drawing the parts you have in hand first and then fitting them together in a CAD program
takes the guesswork out of play and allows you to move forward knowing your parts will fit.
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I decided to machine the adapter first because it was 7075 aluminum and the easiest and quickest to make. Here the inside and outside diameters are milled with a 1.0 diameter, 2 flute HSS end mill.
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Threadmilling the flashlight threads 82.5mm x 1mm pitch using a 6 flute single row thread milling cutter.
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Cutting the adapter off the coupon, same as using a part-off tool on a lathe, using a 5 insert, 2mm wide, 63.5mm diameter grooving tool.
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Here is the finished product after hours of planning, designing, programming and about 1.5 hrs machining.
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Haha Im a hack compared to work I see here, it gives me something to aspire to.

That is simply orsm. Have to love NC machines not that I’d have a clue how to use one. :+1:

OK , next up is the new bezel. I made this from a piece of scrap 316 stainless steel. It is a very tough material to machine.
Here the 29deg front angle, face, and outside diameter were turned on a lathe. It is being parted off in this picture.
The tailstock is inside to catch it when it falls off.
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Here the inside diameters are bored to finish after flipping it around to the opposite end.
There is paper between the chuck jaws and the outside diameter to protect the finish.
Notice the parallel and 2 magnets on the chuck face. That was done to extend the bezel away
from the chuck jaws so it could be faced to finish. The magnets are very strong and the RPM was kept very slow.
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Here are the dimensions used to machine the Bezel. The threads were match fit to the adapter.
Unfortunately I broke an end mill while milling the inside diameter prior to thread milling and
was a bit rattled by that and forgot to take more pictures of the bezel threading. It is easier to thread mill
the metric threads than to do that on a lathe. Doing metric threads on a lathe can be very troublesome.
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Broke an end mill right before finishing the Bezel. Forgot to change “Y axis” number in the program,.
And yes it left a mark on the inside diameter. But the 316ss is so tough, it still did not scrap it. :person_facepalming:
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And here is the finished Bezel.
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Ouch. Looks like it could’ve been worse, though. Great progress since you got rolling :+1: Looking forward to more :slight_smile:

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OK, here is the last part machined, a Heat-sink.
After mounting the 86mm reflector forward of the original position, a gap or space was created even with the longer reflector. So this created an opportunity to add more heat distribution. I had to draw this up on the fly on paper.

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The copper is pressed in with .0005 interference press fit. Copper is very sticky and a light press holds good.
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Finishing outside diameter and parting it out simultaneously. Left .007 thick and broke it out by hand.
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Finished Heatsink at .290 thick.

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