I know I'm a little slow getting this up, but machining Damascus steel is a bit different and took some extra time and concentration (for me anyway).
First, let me just say that this steel is gorgeous. I can't adequately explain it, but I REALLY dig the way it looks. Second, machining it is very different than cold rolled steel or aluminum or even copper. I found that I had to take a pretty deep cut at a high RPM to get a good surface finish. Even then, there is a little bit of imperfection to the finish but a small amount of polishing with 320 grit paper and a scotch brite makes it perfect.
I found myself really stuck for several hours figuring out whether to go with a reflector or an optic. I like reflectors much better than optics, but they occupy a lot more space in the head. I wanted to keep the light short. You see my conundrum. I ended up compromising and decided to cut the reflector that I had shorter. Next, I had to decide how I was going to drive the LED. I had already decided on a 14500 battery. I decided that this light is for Matt and he wanted a light to showcase his Damascus. So, I went with a Qlite with the normal three modes. I already had a UCLp from flashlightlens.com, so that was an easy choice. A McClicky rounded out the parts needed.
Of course, I had to add a little copper into the mix. I decided on a copper pill with just a small shoulder that would separate the head from the body. I like the idea of exposed copper as a contrast to the Damascus.
I measured everything and drew up a plan for each part. My notebook for this stuff is getting pretty full:)
Here is a pic of the Damascus before I started.
Center drilling the head.
Drilling the head
Threading the head for the pill.
Reaming the pocket for the driver.
Driver Pocket
Head and pill assembled.
Drilling the body
After the OD has been machined and polished.
Body sawed off for facing to length and drilling the other end.
Head and body together.
That's it for now. I work 2nd shift today and have some stuff going on tomorrow so probably no updates until Wednesday or Thursday.