A dirty DIY mod

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Kokopelli
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A dirty DIY mod

Well it really was a dirty hack. The patient is an ordinary double C incandescent light with a very weak body and a weak output.

I wanted to try side emitting 1W Led Emitter for the first time on this light. I needed a driver board too but I didn't want to invest in and the worse, wait a month for a driver to come, so I decided to build my own boost driver. The circuitry was a simple one I found on Internet, using 1 PNP, 1 NPN transistor, an inductor, two capacitors, a resistor and a diode. I changed the components slightly, though.

I tried to do my best to squeeze this circuit on a DIY board and the size was enough small to put into a flashlight. Tried this with another 1W led. The star is 20mm for size comparison.

Boost DIY and a 1W led

There came the light.

 Light shone

The current out of the batteries were 420mA but I don't think I could feed the Led with more than 150mA.

Current at tail

It was time to try sku.13286 with the board. I took the contact plate out of the flashlight and soldered the led and board onto this. Isn't the best mechanical connection I know.

 Main led connected

Fron view

I had to make a crappy washer between the led and the board to make an isolation and a better backing for the led. I didn't think the led would need any heatsink at this current.

washer

This time the head lights together.

Head

Rear view. These solder points needs an insulator before making the (+) contact point.

read

So I cut a 35mm film canister into half and made a hat for the driver.

Hat

The final results and a ceiling shot. So this must be the worst spot image ever.

 DIY Done

 

The light is flooder. Light output is on par with other 1W lights, but maybe driven a bit less efficiently. Shot was taken as ISO 800, 1/10 sec, f3.3. Will post some shots of other lights with the same settings if I can.

 

It took just an hour to do this, while our little one was sleeping midday (the only time we can have for our hobbies). I know it might not be worth the bandwidth eaten but I enjoyed this little hack. I hope my second will be building up a double battery XM-L flashlight with serious parts.

 

Thanks for watching.

Seckin

Edited by: Kokopelli on 12/18/2010 - 18:27
brted
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Man, that's an ugly beam. But it works! That's a pretty hard core mod. Thanks for sharing. It's always good to know what other people are doing and what is possible.

Match
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I love it!  There's nothing like building your own driver....that's fantastic.  I wonder if you spritzed a little hair spray on the reflector if it would smooth out the beam?  Might be worth a shot.  

Thanks for sharing this.  I like these kind of out-of-the-box mods...

 

-Match

Kokopelli
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Thanks for all your comments.

Building own driver was fun but I saw how difficult it could be to make a 16mm x 1mm board with %85 efficiency. Still, I plan to make a linear driver with a Mosfet to drive a 6.6V led  with double LiIon batteries, possibly on a bigger aluminum body. That should be a better efficiency light (~%90 at 7.4V), though the heat from a general brand 5W emitter could be higher than a cree.

dorpmuller
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I love it! More ingenious than $$$$ custom lights... try spritzing some clear spray on the reflector and see the beam smooth right out.

 

Rich

"I am the flashlight king! I can light anything!"

Kokopelli
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Thanks a lot, I'll try that spraying trick next.