Best way to secure 20mm triple optic in a p60 host?

Flashlight Modding and DIY Parts
1

Hi all,

as per title i’m just wondering what is the best way to secure a triple optic to a custom p60 pill? The most obvious and easy answer I figure would be to retain the original reflector lens but I would prefer to go without for a cleaner look. I see the more expensive bought off the shelf items have a retaining ring to secure it but is there any cheaper diy alternatives?

The reason I ask is because i’m planning to turn some copper p60 pills from barstock at work and just want to figure out all the details first.

thanks, Lee

2

People have recommended using a washer, to make up the difference in size of the P60 lens opening (~26.5mm?) and the triple optics (~20mm?) but I haven’t found a suitable washer myself, so if you find something, I’d be interested too. I guess it’d have to be blackened or anodized also?

3

Sticking the TIR right up against a glass lens is a really good way to alter the beam pattern of the TIR, in unpredictable and unwanted ways. If you have to keep the lens, there needs to be an air gap between lens & TIR to avoid that.

You can make an adapter of sorts with two pieces of... whatever, with minimal precision work. Cut two rounds the same OD as the original lens. Make a hole in one of them just large enough for the TIR to pass through, and a hole in the other one smaller, to retain the TIR. Stack them together with the larger hole one in back and the smaller hole one in the front. Glue/epoxy (or solder, if you used copper) the two rings together. Seal the TIR into the adapter with a bit of clear silicone RTV around the edge, clean off any excess after it cures.

4

What’s the material round the outside of the optic in this pill?

is that delrin? a press fit as well to retain the optic? I could get a bar of that and machine a ‘collar’ to secure the optics

5

Knocked up a solid copper pill yesterday for a triple led setup but still need to sort out a way of securing the optic in at the moment it’s just pressed in (snug fit). Not bad for a first attempt the second will be alot easier and faster to make.






6

Oh that is just freeking sweet!

Care to share the dimensions of the ring and how much you had to cut it down sir?
Go back and edit your image links…it contains .jpg.html

7

Sorted the pics thank you.

Unfortunately that pill was not made by me! no way far too professional a finish! I was using it as an example of securing the optics that’s all.

8

With what you have made do what comfy said. Just get a thin piece of round copper that just incases the optic to hold it in.

9

Be aware that those boards/optics from KD are a little strange. The locating pins on the TIR are taller than the MCPCB is thick, so they need to be either trimmed shorter or add locating holes in the pill that they can drop down into. The step on the bottom of the legs has to sit flat on the top surface of the MCPCB to get the focus right.

10

Ah yes thanks for reminding me of that as I never trimmed them yesterday. So if I have something slightly covering the edge of the TIR to secure it in position will that affect the beam/light pattern at all seeing that it will only very slightly cover the outside edge of the TIR?

11

You can have the copper piece fan out to cover the pins. Then seal it with rtv.

12

Cutting them down from 20 to ~17mm doesn't visibly alter the beam, so neither does a little overlap at the edges.

13

Cool thanks.

Did you trim that down to 17mm in a lathe? they almost seem too fragile for that.

14

Straight shank carbide in a drill press. The pill/3XP/TIR rotates in a nice concentric circle a fixed distance from the bit due to the two pins clamped in the vise.

15

Impressive diy method