Just off the CNC - Update: It's Alve!

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PilotPTK
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Just off the CNC - Update: It's Alve!

Evening Gents and Ladies,

Thought everyone might enjoy a sneak peak at what I'm working on for myself right now.  The photos attached here are of the base of the 'to-be' enclosure.  I tossed a CD in one of the pictures for size reference.

Machining this was a zero on the fun scale, but it was worth it.  Came out quite nice.  Should look really good once its tumbled and anodized.

Enjoy the pics Smile

PPtk

Front

CD Size Reference

Back Side

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Edited by: PilotPTK on 03/21/2012 - 03:28
Volk
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Wow, impressive work there!

Aux lights for the car? (at least I wish it is Wink)

PilotPTK
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Volk wrote:

Wow, impressive work there!

Thanks very much.  It was really a tough job, so it's nice to have it be appreciated!

 

Volk wrote:

Aux lights for the car? (at least I wish it is Wink)

Exactly.  Going on the brush-guard of my Jeep Grand Cherokee

 

PPtk

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Chicago X
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Wow - beautiful.

I don't even CARE what it is.  I want one.

http://wardogsmakingithome.org/index.html

War Dogs, Making it Home - Rescue Dogs for Returning Vets

PilotPTK
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Chicago X wrote:

Wow - beautiful.

I don't even CARE what it is.  I want one.

Haha.. Thank you!

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edc
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Very nice work. I want one too but I don't have a jeep

 

http://i1193.photobucket.com/albums

PilotPTK
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No need for a Jeep.

It would also make an excellent EDC torch Smile

 

PPtk

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Pulsar
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That would look fine on the front of my xterra. Nice handy work
PilotPTK
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Now I have to convince myself to sit down for an hour or two and finish up the circuit board layout..  Hopefully, I'll have this thing mostly put together in 2 weeks or so.  Can't wait to see the output from 240 watts worth of LEDs Smile

I am currently extremely busy with work. Please do not expect a response from me quickly. I will be dropping in as time permits, but the amount of time I can dedicate to responding to topics and PMs is very limited.

Pulsar
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I'm interested too. I've been contemplating what route I want to go with aux lights on my x, the majority thought is be better off with hid. What emitters you gunna run in that?
PilotPTK
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When I drew this, the cad tool said it would weigh 4.01831 Pounds.  Just tossed it on a (pretty darn accurate) scale.  4.03 Pounds

Color me amazed..

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PilotPTK
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Pulsar wrote:
I'm interested too. I've been contemplating what route I want to go with aux lights on my x, the majority thought is be better off with hid. What emitters you gunna run in that?

XM-L mostly.  The very center will have a couple of XP-Gs for some extra throw.

I considered HID, but I like the solid-state nature of LEDs.  I'm going to pot the entire thing in optically clear silicone.  I should be able to drop this thing off the empire state building and have it still light up after it hits the ground.

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yavi
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5 XM-l + 2 XP-G?

It looks great, it should leave all our poor flashlights in the dark hehe.

PilotPTK
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18 XM-L + 6 XP-G

Yeah.. I think it might beat out the solarforces and sky-rays Smile

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Hikelite
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Looks very nice!

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WOW Most impressive.  If I could do that I would be making my own light bodies.  Sadly I can'tCry

"You are making progress if each mistake you make is a new one."

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yavi
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PilotPTK wrote:

18 XM-L + 6 XP-G

Yeah.. I think it might beat out the solarforces and sky-rays Smile

I looked at the holes inside, but it is obvious I looked wrong hehe.

Wow, that should be a huge amount of light then.

PilotPTK
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What the final assembly is planned to look like...

Final Assembly

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Budgeteer
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Home anodizing or local shop that does it?

kragmutt wrote:

They're gonna send you a green redcat with a black LED.

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That is some sweet work there PilotPTK!

I love the idea.

Are you going to fit some optics to the LED's to focus them or what is your thoughts on that?

~ Ledsmoke ~

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We may have our very own Macs Custom right here on BLF!

Rats, finally sold my 2010 509hp Mustang...now I can buy more lights!

Sold the red one too! Now guess what I drive, doing my penance for 500 hp commuters...

http://dreammustang.com/

http://i884.photobucket.com/albums/ac47/Ha

PilotPTK
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Ledsmoke wrote:

That is some sweet work there PilotPTK!

I love the idea.

Are you going to fit some optics to the LED's to focus them or what is your thoughts on that?

Thanks very much!  Glad you like it!

Perhaps this picture will explain the plan for the optics.

Optics

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PilotPTK
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Budgeteer wrote:

Home anodizing or local shop that does it?

I hate the mess and smell of anodizing 'stuff'.. For the small cost, I have a shop do it to MIL-A-8625 Type III, Class 2 specification

PPtk

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MixoMaxo
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very nice project gz, hurry up! wish to see it in action Smile

How you made the aluminum body?

How to fit and isolate the lens? my laziness make me think to a big rectangle of plexiglas to cover all xD

BetweenRides
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PilotPTK wrote:

What the final assembly is planned to look like...

Final Assembly

Most awesome bike light ever!!!! Can I have one with a bar and a helmet mount option? Cool

PilotPTK
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MixoMaxo wrote:

very nice project gz, hurry up! wish to see it in action Smile

not sure why gz means - but It will probably still be 2-3 weeks before I have it fully built up.

 

MixoMaxo wrote:

How you made the aluminum body?

CNC Machined from a 18" x 4" x 4" billet of 6061 Aluminum

 

MixoMaxo wrote:

How to fit and isolate the lens? my laziness make me think to a big rectangle of plexiglas to cover all xD

I'm not sure I understand your question.  The lenses will be attached to the mounting holes on the circuit board, positioned perfectly over the LEDs on the circuit board.  On the front of the enclosure will be a piece of laser-cut Lexan with an aluminum bezel around the edge.

I am currently extremely busy with work. Please do not expect a response from me quickly. I will be dropping in as time permits, but the amount of time I can dedicate to responding to topics and PMs is very limited.

PilotPTK
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BetweenRides wrote:

Most awesome bike light ever!!!! Can I have one with a bar and a helmet mount option? Cool

Ha! That would be great.  It probably weighs more than your bike though Smile  Just the machined enclosure is a hair over 4 pounds, and that doesn't include circuit board, LEDs, lenses, screws, the lexan and aluminum bezel or the mounting brackets..  Plus, you'll need to supply it with about 20 AMPS at 12V Smile

It would make an awesome bike light though!

I am currently extremely busy with work. Please do not expect a response from me quickly. I will be dropping in as time permits, but the amount of time I can dedicate to responding to topics and PMs is very limited.

BetweenRides
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Yeah, you're right. Please let us know when you've got the build complete. I would love your permission to link to it over at the mtbr forums DIY Light section. I think the biggest bar light I've seen over there is 10 LEDs, but they were pretty small ones, arranged 2x5.

Tony Hanna
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I'll take two! One for the roof and one for the front bumper. Laughing

PilotPTK
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BetweenRides wrote:

Yeah, you're right. Please let us know when you've got the build complete. I would love your permission to link to it over at the mtbr forums DIY Light section. I think the biggest bar light I've seen over there is 10 LEDs, but they were pretty small ones, arranged 2x5.

I'll keep this thread updated with my progress on the build.  Right now, I have to finish the circuit board layout, get PCBs fabricated, build up the parts (LED's, microcontroller, Buck-Boost sections, etc.), debug, and then physically assemble the unit.  Lots to do..

As for linking to another forum - Please feel free.  I enjoy sharing my work and ideas.

PPtk

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PilotPTK
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Tony Hanna wrote:

I'll take two! One for the roof and one for the front bumper. Laughing

Picture not showing up - but I actually have considered selling these once I have the design working and debugged..  I'll keep you informed if I decide to do that..

 

PPtk

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