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

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MRsDNF
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G0OSE wrote:
Very impressed with this so far mate, really good work. Thumbs Up

Yep. Have to agree G0OSE. Love

 

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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Thanks everyone. Blushing
There are many bridges yet to cross before this one is done. It is fun to be here in the mix with everyone.
I initially thought this project would be quick and fairly easy, but instead it became trial and error at the start.
So next will be trimming to length and prepping for mounting the driver. Also a test of all electrical components prior to installing.
My hope is to inspire members to enter the contest and get involved in the forum. Beer

MtnDon
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You  are inspiration!

grin
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It is quite clear you are thinking outside the box. Thumbs Up

pinkpanda3310
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Looks like a lot of work to fill out that head. Couple of weeks left mate Wink

  

CNCman
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Ok, back at the operating table we try to get a heart beat Big Smile
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Swapping a XHP 70.2 from a 20mm star.
I used an electric skillet set to 400 deg to remove and relocate the led.


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Cutting out the copper mounting plate for the led mcpcb.


Drilled and tapped 2 × 2mm x .4mm holes for mounting screws.


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Driver mounting ring.
After punching a .625 dia hole, it needed opening up to .690 diameter in order to fit the driver.


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The momentary switch needed this resistor soldered on it to control the leds brightness. It was very tiny, almost invisible without magnification. It required a sharp pointed tip and steady hands.

JasonWW and gchart helped me by explaining the wiring connections on the momentary switch. It came with blue leds and the driver was not made for a switch with leds and this was my first time wiring one. I have modded lights that will get their lighted switches fixed now Big Smile Thanks guys for Helping Thumbs Up
More wires than driver Shocked


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Mini-360 3A DC Voltage Step Down Power Converter for the cooling fan.

The phillips screw is the adjustment, clockwise lowers the voltage.

Adjusting the 5V setting for the cooling fan.

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Ready to fire it up.

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The switch leds and fan are on.

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Now its ready to mount the driver to part #1 of the head and then to the battery tube.

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The brightness does increase, the camera adjusted and it does not show.


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Next up will be a switch housing and the heat sink assembly and fan mounting.
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MtnDon
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Cool. That IS a lot of wires!

Rdubya18
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You do nice work. That tiny resistor would have most likely been dropped/ lost / generally disappeared for me.
Where do you get those tiny taps ?

MascaratumB
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Shocked Shocked Shocked

CNCman
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Rdubya18 wrote:
You do nice work. That tiny resistor would have most likely been dropped/ lost / generally disappeared for me.
Where do you get those tiny taps ?

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I found small taps on ebay.
https://www.ebay.com/sch/i.html?_from=R40&_trksid=p2334524.m570.l1313&_n...
Rdubya18
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Thanks CNC !

MRsDNF
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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
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Now comes the fun part, making the heat sink.
Yrs ago I worked on jet engines, so I thought it would be fun to make it look similar. Cool

Punching out the center to accept a copper plate that was also stamped out.
This was repeated for each piece.

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Here are the blade disc that will draw away the heat.





Initially 4 sets of blades were going to be used, but it was going to be too long, so 3 sets fit better.

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All the pieces layed out ready for stacking. The blade disks have .5 diameter copper inserts i\pressed in.
The copper spacer inserts are .75 diameter.

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Stacked and prepped with reflow solder on the electric skillet.

Finished soldering as can be seen by the dab of melted solder on top.

You can see the reflow solder melted between the copper inserts making it a solid connection for heat transfer.

The mcpcb will mount on this side with 2 small screws.

Finished with mcpcb and fan mounted, ready to be installed.


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Glue is drying overnight for the side switch.

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Next up will be to finish the side switch and mount the heat sink.
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MtnDon
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I got a big smile reading that and seeing the images.

Rdubya18
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It just keeps getting cooler !

kennybobby
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How did you shape and polish those teeth on the compressor wheels? That thang looks like it could fly.

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

G0OSE
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Fantastic work there. Thumbs Up

CNCman
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kennybobby wrote:
How did you shape and polish those teeth on the compressor wheels? That thang looks like it could fly.

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240 grit sanding disc and scotch bright disc. I twisted each blade with pliers, then sanded and polished.
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gchart
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This is looking amazing CNCman!

CNCman
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Thanks everyone Love

CNCman
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Alright, it is time to put it together from tail to Led, less reflector. Big Smile

Mount and glue the side switch.

Connecting the driver ground wire. Also shortened or trimmed the switch wires and fan driver.

Side switch mounted and finished.

Lights on with fan running after turning on at the tail cap. Big Smile




Finished with the hard part, now the reflector and lens are next to get mounted.

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CNCman
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OK we finished today. Sorry it took to the end time, but it has been an extremely busy 3 months as I’m sure everyone has their challenges this past year. I have enjoyed the build and watching everyone’s entry into this yrs Challenge. It has truly been a challenge to complete the build.
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So we begin mounting the reflector and making the bezel with a special lens. Cool
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It took several heating and trimming attempts to get this finished, removing cracks was tricky.

Alignment was very challenging.

Drilling, tapping, screwing it all together.


Preparing the Bezel for epoxy.



The special green lens from a scrap projection TV.

Bezel finished drying.


Ready for final assembly.



You can see some of the imperfections in roundness that made this part very challenging to finish.

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Beam Shots.



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It has been fun building this Skeleton Light for internal hardware visibility.
Hope you enjoyed it. Good Luck to everyone in the Challenge Big Smile
Remember, its not about winning, just have fun with your friends here at BLF.
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Thanks goes to you Old Lumens and everyone here at BLF. Big Smile
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MtnDon
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! Great concept and execution!

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Wow good stuff. You smoothed out all the edges of your blades right? That musta taken a while to do. I really like the unique clear enclosure you made which allows the internals to be on full display. Means you can’t get away with using those terrible EBL batteries Big Smile

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CNCman wrote:
OK we finished today….

Beam Shots.



Really cool build—adding the green lens was a real surprise at the end, totally didn’t see that coming but i like how you repurposed the TV optics.

It looks like you spotted a man following a woman carrying a baby out in the woods..?

Bonus points for the wooden stand you made, that was a clever idea.

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
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Sunnysunsun wrote:
Wow good stuff. You smoothed out all the edges of your blades right? That musta taken a while to do. I really like the unique clear enclosure you made which allows the internals to be on full display. Means you can’t get away with using those terrible EBL batteries Big Smile

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I was afraid to use 30Q’s because the driver may not survive them.
Yep, that is a point deduction, my bad for not ordering something special.
Only had those ssshhh ebl’s for lower amp use. I had purchased them before knowing not too yrs ago. Facepalm
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MascaratumB
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Shocked Incredible building!!
Great work!

G0OSE
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Fantastic work mate, then again I expected nothing less from you! Smile it was always going to be a masterpiece!
maybe because of the green and it’s size you could name it….. HULK – The inner beast will be released even fits the description!

Rdubya18
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That is one “ cool “ light !

gchart
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Amazing work, CNCman! Really cool getting to see the inards.

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