CNCman's entry to the 8th annual BLF/O-L contest [Handmade light category]

48 posts / 0 new
Last post

Pages

CNCman
CNCman's picture
Offline
Last seen: 1 day 8 hours ago
Joined: 04/07/2018 - 10:10
Posts: 750
Location: Mississippi Gulf Coast
CNCman's entry to the 8th annual BLF/O-L contest [Handmade light category]

Hi everyone Smile
Welcome to the Old Lumens Flashlight Challenge 2020 here at BLF. Smile
.
I will attempt to build a handmade flashlight, it will be called the “SKELETON”. Evil
The intent is to make it transparent, hence the name.
The entire body will be made with clear plexiglass sheet with a little blue plexiglass mixed.
.
Hopefully together we will be successful because this will be a challenge. Big Smile
Good Luck to all entries, it is a Honor to be here with you.
.
It will be an Actively Cooled light using 2 x Efest 21700 3700mAh 30A Batteries, 1 x XHP70.2 led,
86.2mm(D) x 84.7mm(H) reflector, 20mm – FET Driver, 20mm Forward clicky switch with
Spring and PCB, Brushless DC Cooling Fan 40×40×20mm, Mini360 3A DC Voltage Step Down Buck drive,
Clear acrylic plexiglass Sheet 0.125” Thick, and possibly a specialty lens or AR coated glass lens
( it will depend if I can modify one of 3 lenses donated from a projection TV ).
( edited again 11/14/2020 )

CNC & Manual Machinist. Think outside the box too long , cannot find your way back in.

Never give up, Never surrender. Make someone Smile today.

Edited by: CNCman on 11/14/2020 - 11:46
MtnDon
MtnDon's picture
Offline
Last seen: 4 hours 32 min ago
Joined: 08/27/2015 - 18:25
Posts: 3404
Location: Canuk in NM
Smile Good to see you participate.
pinkpanda3310
pinkpanda3310's picture
Offline
Last seen: 10 hours 56 min ago
Joined: 12/28/2013 - 08:45
Posts: 2730
Location: Perth

Good to see you enter again CNCman. Looking forward to it Smile

CNCman
CNCman's picture
Offline
Last seen: 1 day 8 hours ago
Joined: 04/07/2018 - 10:10
Posts: 750
Location: Mississippi Gulf Coast

Just getting started on this years competition. I decided to start with the battery tube and build aft to the tail cap.
This build will be done on the fly because of all the unknowns. So things will and already have been altered from the original design.
.
So here are the original parts in line and it was necessary to down grade the batteries to 18650 from 21700 in fear the driver would not survive the amp load. Also a 32mm mpcb will be used to allow fitting the reflector better.
.

.

.
Here was the first unknown problem, heating and rolling the battery tube. I used heat resistant barbecue gloves and aluminum tubing to heat and roll it into shape. It took several adjustments carefully heating rolling, bending and stress relieving it.

.

.
Guessed at cutting the length and filed it square.

.

.
Cutting a .060 slot the full length for a copper strip to set. This will provide the connection from the negative battery side fwd to the driver.

.
Here is the semi-finished battery tube.

.

.
I will start the tail cap next, it will be tricky building it. Beer
.

CNC & Manual Machinist. Think outside the box too long , cannot find your way back in.

Never give up, Never surrender. Make someone Smile today.

MtnDon
MtnDon's picture
Offline
Last seen: 4 hours 32 min ago
Joined: 08/27/2015 - 18:25
Posts: 3404
Location: Canuk in NM
Thumbs Up Smile
Skylight
Skylight's picture
Offline
Last seen: 13 hours 15 min ago
Joined: 10/01/2018 - 04:49
Posts: 924
Location: Europe

Nice start! Cool Thumbs Up

MascaratumB
MascaratumB's picture
Offline
Last seen: 9 hours 26 min ago
Joined: 10/29/2016 - 12:12
Posts: 5786
Location: Portugal

Looking forward to see this build Wink

G0OSE
G0OSE's picture
Offline
Last seen: 10 hours 7 min ago
Joined: 09/03/2014 - 12:34
Posts: 1674
Location: UK SW

I know what you’re up to here – I can see straight through it! lol

MRsDNF
MRsDNF's picture
Offline
Last seen: 1 day 14 hours ago
Joined: 12/22/2011 - 21:18
Posts: 13458
Location: A light beam away from the missus in the land of Aus.

Nice start CNCman. I can clearly see what your doing.

 

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.

 

gchart
gchart's picture
Offline
Last seen: 3 hours 18 min ago
Joined: 03/19/2016 - 11:57
Posts: 2612
Location: Central IL

Great to see you’ve started up, CNCman! Lookin’ good so far. That reflector looks huge.

Rdubya18
Offline
Last seen: 28 min 55 sec ago
Joined: 10/28/2018 - 18:42
Posts: 382
Location: Ohio

Cool idea ! Thumbs Up

CNCman
CNCman's picture
Offline
Last seen: 1 day 8 hours ago
Joined: 04/07/2018 - 10:10
Posts: 750
Location: Mississippi Gulf Coast

Thanks guys Big Smile
It’s fun to be competing with you all. Beer

CNC & Manual Machinist. Think outside the box too long , cannot find your way back in.

Never give up, Never surrender. Make someone Smile today.

kennybobby
kennybobby's picture
Offline
Last seen: 5 hours 24 sec ago
Joined: 05/10/2017 - 09:13
Posts: 579
Location: huntspatch, alabama

This looks like a fun build in progress. i never knew it was possible to do all the things that you can do bending plastic—you’re like a sheet metal guy bending steel, except it’s sheet plastic. i’m going to school on this one Grad

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

CNCman
CNCman's picture
Offline
Last seen: 1 day 8 hours ago
Joined: 04/07/2018 - 10:10
Posts: 750
Location: Mississippi Gulf Coast

Here is the electrical connection in the battery tube.
I had cut off a strip from a sheet of copper with snips and straightened it in a vice.
After filing one side square, I used calipers to layout a line to file the second side too. 1 hour filing this side.

.

.

.

.
Rolling, bending, flattening in a vice, repeat several times and it is roughed in.

.

.

.
Fitting it up, but not glued in place.

.
Just doing one end for now until tail cap is roughed in.
Kinda strange not working to a drawing, just doing it as it needs it. Any suggestions are welcome Wink

CNC & Manual Machinist. Think outside the box too long , cannot find your way back in.

Never give up, Never surrender. Make someone Smile today.

MtnDon
MtnDon's picture
Offline
Last seen: 4 hours 32 min ago
Joined: 08/27/2015 - 18:25
Posts: 3404
Location: Canuk in NM

Very nicely done! Bravo!

CNCman
CNCman's picture
Offline
Last seen: 1 day 8 hours ago
Joined: 04/07/2018 - 10:10
Posts: 750
Location: Mississippi Gulf Coast

kennybobby wrote:
This looks like a fun build in progress. i never knew it was possible to do all the things that you can do bending plastic—you’re like a sheet metal guy bending steel, except it’s sheet plastic. i’m going to school on this one Grad

.
Trial and error mostly, learn as you go and scrap a few parts along the way. LOL
One thing to know is after heating it and you are molding it to something, the plastic will cool quickly, if you keep trying to bend it too much, it creates stress cracks or will crack after it cools. Also it has to be held in place at its plastic state ( Hot ) until it cools enough to keep the shape desired, good gloves are needed. The battery tube is one of the easier parts, the Head is where the fun begins, doing a cone. Also I learned on the battery tube, you loose .1 length per 1.0 length rolling. I calculated a .800 inside diameter X Pie 3.14 to get 2.5 inches length to cut for the roll. It finished .25 short. So I had to do it again with a 2.75 and it rolled good. I did not foresee that much shrinkage. Beer

CNC & Manual Machinist. Think outside the box too long , cannot find your way back in.

Never give up, Never surrender. Make someone Smile today.

gchart
gchart's picture
Offline
Last seen: 3 hours 18 min ago
Joined: 03/19/2016 - 11:57
Posts: 2612
Location: Central IL

I, too, have never acrylic formed like that. Pretty cool! I can’t wait to see the end result.

MRsDNF
MRsDNF's picture
Offline
Last seen: 1 day 14 hours ago
Joined: 12/22/2011 - 21:18
Posts: 13458
Location: A light beam away from the missus in the land of Aus.

Nice. 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.

 

Umpi2000
Offline
Last seen: 3 days 2 hours ago
Joined: 03/15/2017 - 08:06
Posts: 389
Location: Durban, South Africa

This looks so good! Why not run Aux LED’s through the “skeleton” too?

CNCman
CNCman's picture
Offline
Last seen: 1 day 8 hours ago
Joined: 04/07/2018 - 10:10
Posts: 750
Location: Mississippi Gulf Coast

Umpi2000 wrote:
This looks so good! Why not run Aux LED’s through the “skeleton” too?

. I could not find any lighted switches in stock, but that is a good idea Thumbs Up

CNC & Manual Machinist. Think outside the box too long , cannot find your way back in.

Never give up, Never surrender. Make someone Smile today.

CNCman
CNCman's picture
Offline
Last seen: 1 day 8 hours ago
Joined: 04/07/2018 - 10:10
Posts: 750
Location: Mississippi Gulf Coast

After getting the length of the battery tube decided, it was time to finish up.




.
Here it is assembled but not glued. Next it will be necessary to modify the driver and tail cap switch.

CNC & Manual Machinist. Think outside the box too long , cannot find your way back in.

Never give up, Never surrender. Make someone Smile today.

Rdubya18
Offline
Last seen: 28 min 55 sec ago
Joined: 10/28/2018 - 18:42
Posts: 382
Location: Ohio

This is looking really good !

MtnDon
MtnDon's picture
Offline
Last seen: 4 hours 32 min ago
Joined: 08/27/2015 - 18:25
Posts: 3404
Location: Canuk in NM

Excellent concept, great work. I love it!

CNCman
CNCman's picture
Offline
Last seen: 1 day 8 hours ago
Joined: 04/07/2018 - 10:10
Posts: 750
Location: Mississippi Gulf Coast

Next to make is the tail cap. But the tail cap switch spring is too weak so it will get replaced with a Beryllium/copper spring purchased in a group buy from BlueSwordM. Also replacing the driver spring so the pressure is equal at both ends and spring bypasses too. These mods need to be done prior to molding the tail cap so it can be dimension correctly in relation to the battery tube and eventually the head pieces.
.

.
I prefer to add or remove springs from drivers with the components side up so the risk of some pieces falling off is lower.

.


.
Finished with spring and 20ga wire replacements. More work needs to be done to the driver later.

.
Next up is the tail cap switch, the spring is very soft with braided bypass. New spring and 20ga bypass and a connecting spring will get added.


.
Stripped and prepped.

.
Solder the bypass first.


.
Next solder the connecting spring.

This spring is cone shaped to allow room for the battery negative end to pass by.

.
Next episode will be molding the tail cap and its parts.

CNC & Manual Machinist. Think outside the box too long , cannot find your way back in.

Never give up, Never surrender. Make someone Smile today.

MtnDon
MtnDon's picture
Offline
Last seen: 4 hours 32 min ago
Joined: 08/27/2015 - 18:25
Posts: 3404
Location: Canuk in NM
Quote:
This spring is cone shaped to allow room for the battery negative end to pass by.

P60 dropin spring?

CNCman
CNCman's picture
Offline
Last seen: 1 day 8 hours ago
Joined: 04/07/2018 - 10:10
Posts: 750
Location: Mississippi Gulf Coast
MtnDon wrote:
Quote:
This spring is cone shaped to allow room for the battery negative end to pass by.

P60 dropin spring?


.
It was straight or cylindrical until i stretched it on one end and compressed the other end. I had purchased a variety of springs from Aliexpress last year. Only had one like this and i’m trying to find another substitute for the head end. Beer

CNC & Manual Machinist. Think outside the box too long , cannot find your way back in.

Never give up, Never surrender. Make someone Smile today.

MtnDon
MtnDon's picture
Offline
Last seen: 4 hours 32 min ago
Joined: 08/27/2015 - 18:25
Posts: 3404
Location: Canuk in NM

Oh yeah, a P60 is not conical. They are straight, 21mm x 13mm long. I measured one.

MRsDNF
MRsDNF's picture
Offline
Last seen: 1 day 14 hours ago
Joined: 12/22/2011 - 21:18
Posts: 13458
Location: A light beam away from the missus in the land of Aus.

Nice work. 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.

 

CNCman
CNCman's picture
Offline
Last seen: 1 day 8 hours ago
Joined: 04/07/2018 - 10:10
Posts: 750
Location: Mississippi Gulf Coast

So here we have the body of the tail cap cut off. The battery tube measured .970 to 1.0 diameter, so PI x diameter = circumference + .1 per inch added for shrinkage. 3.1415 × .985 = 3.094 + .31 = 3.404 long x 1.5 wide.
Of course these are ball park figures used to rough it in shape.
It has to be pretty hot to mold by hand, you have to prepare and plan everything before beginning, the doing is trial and error. LOL
.

.

.

.
Just a tad too long, so it needed a trim, about .050 inch.

.
Some filing to finish.

.
It is necessary to make things longer and trim to length afterwards, the plastic gets distorted on the edges.
Of course rough and finish filing is always a must.

.
The small gap will not exist when finished.

.
Rough cut pieces for the switch and cap.

.

.
Dremel tools are priceless Love

.

.

.
Two clearance pockets were needed for the electrical connections.

.

.

.

.
No parts are perfectly round, so tiny notches were made to orientate everything and the finish filing was done to match.

.

.
Here it is, but not fastened together just yet. I had some trouble with the 2 × .4 mm tap, that fix tomorrow. Wink

.

.

.

.
So far so good, I was concerned it would be impossible to make, but just one piece at a time is working. Beer
.

CNC & Manual Machinist. Think outside the box too long , cannot find your way back in.

Never give up, Never surrender. Make someone Smile today.

gchart
gchart's picture
Offline
Last seen: 3 hours 18 min ago
Joined: 03/19/2016 - 11:57
Posts: 2612
Location: Central IL

Great work! I’m really enjoying seeing this come together.

MtnDon
MtnDon's picture
Offline
Last seen: 4 hours 32 min ago
Joined: 08/27/2015 - 18:25
Posts: 3404
Location: Canuk in NM
Thumbs Up Beer What more can I say?

Pages