grins 8th annual old lumens machine made entry

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Agro
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I love what you do grin. Smile

Yokiamy
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Awesome work, great job!
It looks fairly easy, but i know it isnt

grin
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Thanks, anyome can do this if they are determined enough. But it is pretty exciting being able to make custom one off reflectors. I have also been thinking of ways to manufacture parabolic mirrors to make them more available to people with smaller budgets. Soon I may have the space to setup a dedicated workshop to do it.

MtnDon
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Wow! What a marathon polishing session. Thumbs Up Beer

kennybobby
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i thought the use of a plastic template was a brilliant idea. How did it survive all the sanding operations?

Now i used to think that i was cool,
drivin' around on fossil fuel,
until i saw what i was doin',
was drivin' down the road to ruin. --JT

Scallywag
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Impressive. Took as much time to polish as I spent cleaning out my garage (though I spread that across a week)

MRsDNF
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Agro wrote:
I love what you do grin. Smile

So true Agro. Could not have said it better. 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.

 

grin
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kennybobby wrote:
i thought the use of a plastic template was a brilliant idea. How did it survive all the sanding operations?

The first one I ran into the job a few times which caused the damage to it. The second one didnt wear at all. The profile doesnt actually touch the mirror it is just to push the paper onto the job. Once the tension on the paper is even as it moves between the profile and mirror it is time to move to the next grit.

grin
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So the primary mirror is just about done so I will leave it at that for the time being. Next I turned the billet around and cut a bit Of material for the drum and bezel.

The light comes through the vertex of the primary and there needs to be something to condense the light for the secondary hyperboloid. A lens would work but I have chosen to use a 50mm hemispherical reflector because I have a bit of practice cutting them and I cant grind a lens. Yet. Big Smile a few pics will explain how I do it except handle sanding 8t with 1500 and 2000grit.




I cut the chatter marks out turning the lathe by hand and end up with this.

And ready for final polish.

kennybobby
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grin wrote:
I cut the chatter marks out turning the lathe by hand and end up with this.

That’s a beauty.

i have a cutter bit like that with one side ground down so it’s not trying to cut both sides at the same time. That is a huge contact surface to cut, but it sure turned out great with all your pro tricks.

That chatter reminds me of the reflector surface in a Convoy, like they put some chatter marks in the reflector mold that shows up in the plastic part.

Now i used to think that i was cool,
drivin' around on fossil fuel,
until i saw what i was doin',
was drivin' down the road to ruin. --JT

MRsDNF
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Nice. Beer
More black fingers to come.

 

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.

 

CNCman
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If you ever need a job as a Machinist, let me know Cool

Zandar
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Great project and very inspiring, I sent you a PM.

 

Zandar

 

grin
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Little bit of progress drum is made the billet for led heatsink driver/battery compartment is threaded


MtnDon
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Shocked Wow!!
MRsDNF
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MtnDon wrote:
Shocked Wow!!
Yes to this. 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.

 

Lothar
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I love your vision and determination grin! Beer

Current Collection:

BLF: BLF-GT90, BLF-GT70 (CW Sliced), BLF GTmini, BLF-LT1; 

BTU: Shocker (3 x SST-40 @ 8A)

Solarforce: L2P (XM-L2 U3 @ 4A), MPP-1 (XP-L HI @ 6A), MPP-3 (3 x XM-L2 U2 @ 12A), M6 (Nichia 319A @ 6A), M8 (XHP-50.2 @ 9A), 9x (9 x XM-L2 U2 @ 2A)

Coming Soon: Lumintop: BLF-GT4; 

pinkpanda3310
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I hope you get time to finish this grin. I’m lovin’ what you’ve come up with so far. Even if you don’t finish in time please finish it eventually Smile

  

grin
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I will be back on it this week, everything I have ordered is here. Today I should have the hyperbola profile for the secondary ground. I have made the new profiles from 45mmx8mm high speed steel and they work very well. My lathe doesnt have enough power so I turn the chuck by hand with a 15inch shifting spanner.


I have 5000 7000 and 10000 grit wet and dry sand paper to finish them before polish.

grin
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After a major setback I have had some progress. This I how I make the profiles.
First I plot the curve on graph paperand epoxy it to the HSS blank with high temperature urethane.

Clean up

Honed with a diamond steel

CNCman
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grin wrote:
After a major setback I have had some progress. This I how I make the profiles.
First I plot the curve on graph paperand epoxy it to the HSS blank with high temperature urethane.

Clean up

Honed with a diamond steel
!{width:40%}https://i.imgur.com/CSduG6Q.jpg!

.
Not enough time to get it to you, But next time you need a template, let me know and I will make one for you. Wink
Free, of course Smile
Great Work on your build Thumbs Up
grin
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That would make it so much easier for accuracy, do you make the tempate from sheet metal? Im all ears Glasses the 2 I have done are not exactly right. Here is a photo of one tuned for a w30 engine that is just cut and polished the cut marks are visible.

This is the comp lights primary the mistake is obvious

grin
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The drum and bezel are done I will post some photos soon.
Original I wanted to use 170mm borosilicate 3d printer bases for a lens. For the secondary mirror mount I needed a hole so I ordered 5 and broke 4 so I am resorting to PMMA acrylic sheet. I should have that done tonight. This is the expensive blunder.



Robin Dobbie
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grin wrote:
This is the expensive blunder.

That’s my hole existence.

CNCman
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grin wrote:
That would make it so much easier for accuracy, do you make the tempate from sheet metal? Im all ears Glasses the 2 I have done are not exactly right. Here is a photo of one tuned for a w30 engine that is just cut and polished the cut marks are visible.

This is the comp lights primary the mistake is obvious
!{width:40%}https://i.imgur.com/UbxWygg.jpg!

.
Probably .125 aluminum sheet. I can bevel one side to a sharp edge or a .030 flat.
I need the radius. It will be milled on a cnc. Wink
Rdubya18
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That is really beautiful work !

grin
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CNCman the only problem is that with a parabola and hyperbola there is no actual radius. So to get one cut with a water jet or machined I am not exactly sure how I get the formula to program the machine. The reason being I worked out how to draw them without using a formula just a compass and ruler.

kennybobby
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howdy grin, there are some really cool tools available on the wwwebsticle which can generate the equation or coordinates for your curves. If you wanted to post up a picture of a template curve then we could convert it to g-code, probably CNCman already knows all this too.

Some ray traces:

Now i used to think that i was cool,
drivin' around on fossil fuel,
until i saw what i was doin',
was drivin' down the road to ruin. --JT

grin
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Kennybobby here are some detailed drawings of the plotted curves the grid paper is 1mm the drawing is full scale. I will take on CNCmans suggestion and make some templates to check the HSS profiles. The primary has a bandwidth of approximately 160° which is perfect for a 3mmx3mm led so maybe there might be some interest in a group buy of a 150mm parabolic reflector. The equation would have to be generated for that diameter and bandwidth.

Zandar
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Wow, your work is just amazing! I can't wait to see this light in action!

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