5th Annual BLF OL Comp Build. Can A Flashlight Flash? The Naked Truth. Update post 151. Night shots added. 16.12.171

Travel/vacation in China with his Dad.

OH thanks! I missed that and begun to get really worried

Dnf is back severely jet lagged and worn out after a whirlwind, non stop tour of China with an amazing bunch of people in an amazing country. The train topped out at 308 KPH and the party was documented by many confused Chinese passengers but that is another story. :slight_smile:
Thanks for all the comments and work will continue on the light in the near future when the body is back to normal (no comments please :weary: ) and the chores around the house are caught up with, if thats ever likely to happen. :stuck_out_tongue:
Theres no sorcery in this light TK but there is plenty of your sorcery in a lot of other lights around here. :smiley:

WOW, Great build I will be keeping track of this keep it coming.

Thanks Rat. Stay tuned. :slight_smile:

This picture shows where the driver sits. The two through holes are for the led positive and negative wires from the driver. The dimples are to make sure the driver doesn’t short out in these places.

This is the opposite side to the above picture showing the two through holes. The wiring comes out where the fan is positioned in the next level of the head.

Two grooves were machined for the wiring to clear the fan area. The grooves end where the holes are for the wiring to travel through the fan housing and come out in the position of the negative and positive for the leds. Hope that makes sense.

The following two pictures explain a little better than I.

And to end this groovy session the plate where the reflectors screw into was slotted on the back to allow the wiring to connect the three leds in series.

As proof of concept the wiring and leds were tethered together and fed some power. The voltage at the leds was 1 volt higher at 2 amps than calculated from the djozz testing chart. This was a good thing as the fan will be getting a higher voltage, hence spinning faster than first thought.
It is expected each led will have 6 amps on high when completed.

Next up was the slotting of the fan housing to allow air to travel into the fan and be expelled out through the copper cooling pipes.
A marker was used to mark the non machined areas and act as a map. I did not want to slot where the six through holes for the retaining capscrews and two wires travel through.

Lots of 19/64’’ holes were drilled.

The slots were then finished of with a 5/16’’ end mill.

And the end result is lots of caverns.

Whoo-Hoo!!! :+1:

We want more :slight_smile:

I wanted to make this reply just for clarification.

This part below

Goes in between these parts below

It’s not clear but is shown here

I went back and checked closely so I thought others might be doing the same. Sorry if it seems like I’m high jacking your thread Moose. Fantastic work BTW. I get the impression this light will have even more heft than your OL Tribute lights.

Correct pp on the way its assembled.
As far as heft goes this light should be a lot lighter in weight than the OL tribute light. Everything is lighter when its naked. :laughing:
The fan housing will be a lot lighter than what it is here. I have no idea what the final shape will be but a lot of material has to go.

Yeh, a lot of people have trouble losing weight :zipper_mouth_face: A strict diet of lathe and mill for your light :smiley:


This is just awesome to watch! Excellent job sir! :+1:

Looks awesome :beer:

Your talent is really starting to shine :smiley:

Cheers David

Pun taken pommie. :slight_smile:
My wifes not sure where its shining from though. :person_facepalming:

The centre section of the head assembly which holds the fan was profiled to loose a bit of weight.

The pink chalk and hand file was put to good use again bevelling the edges of several parts to try and break up the blockiness look.

The reflectors threaded into their retainer. The cap screw heads had to be profiled for clearance on the reflectors.

A shot with a ruler to give an idea on the size of the reflectors assembled without the bezel.

This shows one of the reflectors sitting on a C8.

A group hug of all the machined components. It seems such along time ago that the machining started.

The part the reflectors screw into.

The top of the bezel.

The centre of the head which holds the fan.


Driver holder and the part that the battery tube screws onto.

And finally the battery tube.

The finish is getting very close. :slight_smile:

Amazing work, I wish you had got this finished for the comp :+1:

I commented somewhere before the comp started I could build a light and finish or build a light I wouldn’t finish. I chose the later knowing there would be a good chance I wouldn’t have time to build it. At the time I had this idea in my head and wanted to build it so here it is.
If I hadn’t gone to China as well I may just have finished it. :slight_smile:

Cool, I understand that, you can see the quality work in this takes a lot more time, thought and effort :+1:

Man, that is some serious engineering and work going into this one.