Boost 519A mule build: "Phobos"

At least 50 times a day, someone will tell me “We lack efficient, high output, high CRI mules”. Well this is it, the voices in my head have won. I have dubbed it “Phobos”.

“Phobos”

  • Convoy S21B gray host
  • 4 x Nichia 519A 5000K DD in mule config
  • Efficient Convoy boost driver (6V8A)
  • 4A per emitter (2S2P)
  • Est. ~ 4000 lumens at turn on (P42A)
  • Illuminated RGB switch
  • Copper DTP, Noctua NT-H1 thermal paste
  • Extra copper heatsinking, bypassed springs
  • 3D printed centering ring
  • Optional Wurkkos 20350 body tube

So Convoy has released its XHP70.3 6V8A 22mm driver. I thought this would be the perfect base for a new mule build. @Simon_Mao


This has been a very frustrating build, especially since my dog ate my flux syringe.

It’s alive!

I love how the RGB switch desyncs after a while:


It does get pretty toasty, real quick on turbo. Will the 3D printed ring hold? We’ll find out.

The “mule spacer” are multiple demasked copper MCPCB’s, soldered together. These also function as a bit of extra heatsinking. I used solid copper wire as centering dowels.

Positioning the centering ring accidentally decapitated one dome, so I removed all of them.

I didn’t build this for the high turbo output, but rather the convenient lower output modes.

09/22/23 - Added some beamshots + V2.0 ring:





Any feedback or ideas are welcome!

10 Thanks

You can paint that printed “reflector” in white or chrome .

2 Thanks

Looks good! Those quad boards have been around for years but I’ve not seen many builds with them, I put one with 4x 519s in a convoy L6 with a shorty tube and driver from Hank. The beam is a bit doughnutty and I need to tidy up the soldering.

1 Thank

Yeah, I can print in white! Thought the gray was best for the gray body.
Just did a 5 minute turbo run and it didn’t have any impact on the material.

I’m already contemplating V2.0 with cutouts to expose the wires.

1 Thank

Nice job.

Is that spacer resin printed?

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Yeah, this quad 6v mule has been on the list for a while. And that L6 sounds like a real frankenlight! Got any pics?

Yes it is, @Hoop . It was the simplest option to hide the ugly generic “CREE” board and double as a spacer.
The design definitely needs some refining, but initially I I wasn’t sure if it was going to hold up to the temperature. Looks fine for now. Will add some new variants soon.

Nicely done. Could we trouble you for some beam shots?

I think I have some of those boards on the way, in theory at least - not sure if they’re ever going to arrive.

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I have added them in the OP.
I find it very peachy of colour and it even holds its own when compared to the 219B mix. I will try to get a green AR coated lens, as the purple ones are detrimental to -DUV.

I am desperately looking for a “normal” 20mm 2S2P 3535 for TIR optics… I think it doesn’t exist, and will have to design my own.

Thanks for the beam shots!

Do you mean an optic for that tight 2x2 configuration? I don’t believe I’ve seen anything like that. I think the LEDs are too close for four individual TIRs like a more “normal” quad optic.

Like @Quadrupel said, printing that neat spacer/gasket/reflector thing in white could give it some additional throw, if that’s what you’re looking for.

Thats a pretty cool build, good job.

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If I’ve got some time when I’m next back in November, I’ll redo the solder and take pics at the same time.

Also have a FC40 led I want to try. The driver is a tad low powered for these LEDs, I will have to see if there’s a component I can change to give more output.

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No, just a standard single optic for a quad config, but 2S2P instead of 4P. Hank uses 4S, but I’d rather do 6V.

Thanks!

You might be able to modify the 4P pcb to 2S2P by cutting the traces, I’ve seen it done.

2 Thanks

I found one at MTN (20mm MTN Quad XP / 219 DTP Copper MCPCB)! Sadly, I am from Europe. So shipping is going to hurt.