6th Annual BLF Handmade entry - Big_Sam

Big_Sam · 2018-09-09T23:32:48.000Z

Hello BLF!

I am quite new here, although been lurking for a couple of years trying to learn! I had not seen the build contests until I stumbled on them this week, it looks great! Like a lot of folk I am short of free time, so I have tried to design my build to be easy to do in my garage and using just the tools I currently own.

I had thought of a lantern before I saw the other build threads, sorry it’s another one! I own a lot of torches (what we call them this side of the pond) but currently no lanterns, so this could actually actually be a useful bit of kit. I have never built any sort of torch/led device before so it’s quite new to me. I know very little about drivers etc so have been frantically researching the simplest setup and have decided to go with 3 x XP-L HI and 3 x driver boards (each with 3 x 7135) running off 3 x AA eneloop Pro. The reason for using three drivers is to keep it simple, one switch supplies a common rail and powers them all. The XP-L HI is flat so will be good for flush fitting to the acrylic rod.

The design is based on fully diffused light using frosted solid acrylic rod (perspex) with the LED projecting into the end of it, I hope this will provide enough light with wasting too much. The housing is made from solid brass so I can fully polish it and it will act as a reflector (lovely warm colour too!) from the 3000k LEDs.

I decided to use AA as I have loads and easier for me.

A couple of concept sketches shown below.

I’m away on holiday for two weeks now, so I have ordered the materials and they should hopefully arrive by the time I return.

I have not figured out where the switch will be yet, but most of the rest of it should (in theory) be ok. Some of the tolerances are far too ambitious for using a pillar drill, so fingers crossed!!! :person_facepalming: The scalloped sides will have to be cut with a offset holesaw…what could possibly go wrong :laughing:

I would appreciate feedback if I have made any fundamental mistakes so far…!

Cheers, Big_Sam

Materials Ordered:

60mm AF Brass CZ121 hex bar

19mm frosted acrylic rod

Cree XP-L HI U6-7C 455LM 3000K LED Emitter
10W / max. 3000mA / warm white / on 16*1mm board

3* AMC7135 4-Group 2~5 Modes LED Flashlight Driver Circuit (Nanjg AK-47A)
3.0V ~ 4.5V / 1050mA constant current / 17mm

20mm drill bit (I was going to avoid buying new tools, but as I will have to flat grind the 20mm for spot facing the LED mount I bought a cheap drill bit to sacrifice)

MascaratumB · 2018-09-09T23:54:47.000Z

Hey Big_Sam,

This really is a great entry Welcome to BLF and enjoy, first of all!
I will be looking at the build of this project, although lots of other members will help you more!

Still, good work on this, and it looks interesting

Don’t forget to notify member the= by PM to add your thread on the contest thread . :+1:

MRsDNF · 2018-09-10T00:11:26.000Z

Good to see you here Sam. All the best for the build.
Just wondering if you ran all the leds in parallel of one 2.8 amp driver. Maybe make thing a bit simpler.

Big_Sam · 2018-09-10T00:46:50.000Z

I think you are probably right, what made me lean towards individual drivers was reading some threads about parallel led and some of the downsides. I’ll do some more research and see if it would suit this project better.

Thanks Sam

CRX · 2018-09-10T12:24:30.000Z

Welcome, interesting design :+1:

Flashy_Mike · 2018-09-10T13:38:02.000Z

Very interesting and futuristic design!
Welcome to the lantern gang!

DavidEF · 2018-09-10T14:37:42.000Z

I like the design of this lantern! It’s very unique! Welcome to the contest!

Big_Sam · 2018-09-10T14:49:50.000Z

Thanks for the welcome!

Update (first post updated also)

Materials Ordered:

60mm AF Brass CZ121 hex bar
19mm frosted acrylic rod
Cree XP-L HI U6-7C 455LM 3000K LED Emitter
10W / max. 3000mA / warm white / on 16*1mm board
3* AMC7135 4-Group 2~5 Modes LED Flashlight Driver Circuit (Nanjg AK-47A)
3.0V ~ 4.5V / 1050mA constant current / 17mm
19.5mm drill bit (I was going to avoid buying new tools, but as I will have to flat grind the drill bit for spot facing the LED mount I bought a cheap drill bit to sacrifice)

FmC · 2018-09-11T20:48:24.000Z

Hey Sam, good luck with your build! :+1:

Big_Sam · 2018-09-21T00:30:48.000Z

!http://tinypic.com/r/10o2ssn/9!

Some of the raw materials have arrived, that lump of brass is seriously heavy! Waiting for LED and drivers to arrive. Hope to get some more detailed designs done next week.

Jerommel · 2018-11-04T20:07:37.000Z

Good luck with the build.
Following all of you.

gchart · 2018-11-24T17:47:57.000Z

Hey Big Sam, how’s the progress going? Or are you wanting to do a big last-minute reveal?