Skylight's 8th BLF OL contest entry, modified flashlight [waiting for parts]

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Skylight
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Skylight's 8th BLF OL contest entry, modified flashlight [waiting for parts]

Mon, 10/26/2020 First update: Host chosen, waiting for parts

I have chosen the host and leds that I will use for this modified flashlight.

I already have the host, ordered it one and a half years ago from Taobao, forwarded it with a Taobao agent. The flashlight is sold only as a host and is called the Dongdonghai D8A. I also have the long 8 18650 extension tube on order.

The DDH D8A is similar to the Astrolux MF01 but a little longer and with the head diameter of a Sofirn SP70. Below is a size comparison of the three flashlights.

I have planned since I ordered this host to modify it somehow instead of using the original configuration. To see how it works I put in a single XHP70 led with a TA driver. It works well and has a nice beam but it has not seen much use because I already have a few flashlights with a single XHP70. The DDH D8A is big enough for a more powerful configuration.

This is the host for my build, the DDH D8A.

With hot glue I made a transparent switch cover instead of the red one to let the light of the lighted switch through. I will need to replace it with a more flexible rubber because it is too stiff and gets sticky when warm.

These are all the parts of the host and a size comparison with the Emisar D4 to show you how big the reflector is. It has 80mm diameter and is 70mm high.

Some measurements

First, I wanted to use a quad or triple reflector with XHP70 leds but then this seven-leds-reflector appeared on Kaidomain. Now I want to fit it inside the D8A with seven XHP70.2. Cool

The reflector is a little too big for the front opening of the flashlight and the led holes are too small for the XHP70 leds. I will need to take away 1.5mm from the outer edge of the reflector and widen the reflector holes from 8 to 10mm. Then I need to build a copper spacer to fill up the empty 4-4.5cm of the longer reflector as the multi-led reflector is only 3cm high. Even if it does not fit yet, I already like the look of this seven-led-reflector in the D8A.

Currently I am waiting for the XHP70 leds and I will also order the copper for the spacer.

What I have

- Host Dongdonghai D8A
- 7x reflector
- Copper rod and 65mm plate for the spacer
- Soldering paste, thermal paste, drill, metal saw, dremel and other material

What I need

- 7 XHP70.2 leds (3× 3000K, 4× 5000K)
- More copper discs for the spacer
- 8 18650 tube
- Maybe a Lexel driver? (with resistors, not sure if the 7135’s can handle 7 XHP70 or will overheat)
- Aux led boards?

Thu, 09/17/2020 Original OP: entry, brainstorming

This is my topic for a modified flashlight for the 8th BLF Old Lumens contest.

I still have to decide which host to use and what leds and driver to put inside.

Could be a big host with optics and SST20 or a few XHP70 in a reflector, don’t know yet.

Stay tuned! Cool

Edited by: Skylight on 10/26/2020 - 16:15
Skylight
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MascaratumB
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Go for it Wink
Good luck with the mod!!

Scallywag
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Well, I’m looking forward to it (and subscribed to the thread) Thumbs Up

Old Lumens Contest 2020 - Hand-made light category

ZL SC62(w) | Jaxman E2L XP-G2 5A | Purple S2+ XPL-HI U6-3A | D4 w/ Luxeon V | RRT-01 | Purple FW3A, 4000K SST20 | Baton S1
Boruit D10 w/ Quadrupel Fet+1/Anduril | EagTac D25C Ti | DQG Slim AA Ti | Jaxman E3 | UF-T1 by CRX | Olight S15 Ti | Nitecore EX11.2
L6 XHP70.2 P2 4000K FET+7135 | Jaxman M8 | MF02 | Jaxman Z1 CULNM1.TG | Blue S2+ w/ ML Special | Thrunite T10Tv2
Supfire M6 3xXHP50.2, Sofirn C8F, Unfinished: Sofirn SP70, IYP07/Tool AAA hot-rods, Jetbeam E3S
Others: Nitecore EC23 | Nebo Twyst | Streamlight ProTac 1AA | TerraLux LightStar 100

CNCman
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Skylight, Big Smile Happy to see you are in the competition 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.

pinkpanda3310
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Looking forward to seeing what you come up with Skylight

Skylight
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Thanks for your encouraging comments, MascaratumB, Scallywag, CNCman and pinkpanda3310 ! Thumbs Up

After a month, I have made up my mind which host and led configuration to use in my OL contest modded flashlight this year.

I updated the OP with pictures of the host and the reflector. It will be a big host with 9cm head diameter and optional 8 18650 tube, a heavy copper spacer and seven XHP70.2 leds. Love

MRsDNF
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Good to see you have the design nailed down Skylight. Looking forward to the mod. Thumbs Up

 

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.

 

MtnDon
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That should be some powerful light! Thumbs Up

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MtnDon wrote:
That should be some powerful light! Thumbs Up

He wants to make it a sky…light Big Smile Cool
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Thanks for the nice comments, MRsDNF, MtnDon and MascaratumB. Sorry if I am replying late but here are the updates.

A few days ago I drilled out the holes of the seven leds reflector. I used a 10mm drill bit.

Before drilling

Half done with drilling

After drilling, I removed sharp edges and cleaned the reflector with air. It looks nice again and the holes are a little bigger now.

The switch retaining ring had to be drilled, too, to allow fitting a Convoy L6 switch cover. The self-made silicone covers did not work properly.

Switch retaining ring before drilling


After drilling and filing


Last Thursday five XHP70.2 leds arrived. I will use four of them in this flashlight. They are 5000K 90 CRI with N2 3C bin. I bought them at the HotRed Official Store on Aliexpress. XHP70.2 90CRI

Compared to a XHP70.2 P2 3A with 70 CRI (bottom right corner) it is clearly visible that these leds have the for high CRI leds typical orange phospor cover.

The four XHP70.2 look great in the reflector. The for now empty spaces will be fitted with three XHP70.2 P2 7A 70 CRI leds to achieve a rosy 4000K light.

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Someone likes walls of light Big Smile

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MascaratumB wrote:
Someone likes walls of light Big Smile

It would appear so. 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.

 

Skylight
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MRsDNF wrote:
MascaratumB wrote:
Someone likes walls of light Big Smile
It would appear so. Love

That is true indeed. Especially high cri and rosy walls of light. Love

But I hope it will give me a big hotspot with a little throw as well.

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This is gonna be nice ! Thumbs Up

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Wow 4*XHP70 is going to be Sooo  bright (and HOT) Wink

A bit off topic but what is your opinion on the Deko drill? seems like it is better than most crappy Chinese power tools.

 

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Rdubya18 wrote:
This is gonna be nice ! Thumbs Up

Thank you, Rdubya18. Smile

YuvalS wrote:
Wow 4*XHP70 is going to be Sooo bright (and HOT) Wink

That’s for sure. I added some new pictures below where you can see that I will actually use 7 XHP70 with a big copper spacer underneath.

YuvalS wrote:
A bit off topic but what is your opinion on the Deko drill? seems like it is better than most crappy Chinese power tools.

I didn’t want to make an advertisement for the Deko brand Innocent but it is a great drill. It is one of the few drills on Aliexpress that is brushless. It is said that brushless motors are more efficient, stronger and better than brushed motors. The Deko drill is indeed strong with 58Nm torque and it even has an impact mode for drilling walls. It has a 40Wh battery that seems to last forever, two speed settings and a very handy percentage display on the battery pack.

I am not an expert in drills but compared to the old drill with Ni-MH batteries that I used previously this is a whole new world. So far, I found no flaws with this Deko drill and I would recommend it. [end of advertisement Wink ]

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Last week the other three XHP70 leds for my project arrived, together with the long tube for 8 18650 batteries.

The four XHP70.2 5000K 90 CRI (N2 3C) and the three XHP70.2 3000K 70 CRI (P2 7A), in the right picture the configuration they will have:

The seven leds reflector is full now. Big Smile

Here is the long tube, together with the battery carrier:

What I did in terms of modifying was to grind away part of the egde of the reflector with my dremel to make it fit into the flashlight.

It went quite smoooth. I feared to scratch the reflector with the aluminium particles but they went outside and left the reflector untouched.

Before

During work

Almost there …

… and it fits.

The edge is a bit textured now but not too rough so I will leave it this way.

Current status

CNCman
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Sweet light Skylight Cool
I really like this very challenging mod your doing. Great job and I’m looking forward to more pics Love
. 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.

MRsDNF
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The torch looks finished on the outside. Thumbs Up

 

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.

 

Scallywag
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With a good FET you can get 7000 out of the 70.2 pretty realistically… Wonder if with 7 of them you’ll hit 50k (however briefly)?

Old Lumens Contest 2020 - Hand-made light category

ZL SC62(w) | Jaxman E2L XP-G2 5A | Purple S2+ XPL-HI U6-3A | D4 w/ Luxeon V | RRT-01 | Purple FW3A, 4000K SST20 | Baton S1
Boruit D10 w/ Quadrupel Fet+1/Anduril | EagTac D25C Ti | DQG Slim AA Ti | Jaxman E3 | UF-T1 by CRX | Olight S15 Ti | Nitecore EX11.2
L6 XHP70.2 P2 4000K FET+7135 | Jaxman M8 | MF02 | Jaxman Z1 CULNM1.TG | Blue S2+ w/ ML Special | Thrunite T10Tv2
Supfire M6 3xXHP50.2, Sofirn C8F, Unfinished: Sofirn SP70, IYP07/Tool AAA hot-rods, Jetbeam E3S
Others: Nitecore EC23 | Nebo Twyst | Streamlight ProTac 1AA | TerraLux LightStar 100

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Just like CNCman said this looks like a challenging mod. Looking good so far Beer

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CNCman wrote:
Sweet light Skylight Cool I really like this very challenging mod your doing. Great job and I’m looking forward to more pics Love . Beer .

Thanks CNCman. I never did a mod with 7 XHP70 before but I hope to get it right.

MRsDNF wrote:
The torch looks finished on the outside. Thumbs Up

True. Inside, the heart and the brain are missing, leds and driver. Wink

Scallywag wrote:
With a good FET you can get 7000 out of the 70.2 pretty realistically… Wonder if with 7 of them you’ll hit 50k (however briefly)?

50k lumens would be an optimistic but nice lumen value. Love If the FET can handle 70-80A I might reach that. However, my aim is more like around 30000 lumens which is already plenty. To handle the heat well I will solder the led MCPCBs to a copper plate and maybe add a little copper piece as heatsink on the FET.

Skylight
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pinkpanda3310 wrote:
Just like CNCman said this looks like a challenging mod. Looking good so far Beer

Thanks pinkpanda3310. Smile I chose a challenging mod on purpose because if it was not for the contest I would always postpone it. The contest gives me the right motivation to finish this mod within a certain time limit.