Convoy L2 build finished, but...

Flashlight Modding and DIY Parts
1

I have no idea how long it’s going to last!

The reason is that, I have gone through two Lightmalls “5A” drivers that have been resistor modded to give a theoretical 5.8A. The light worked initially, but, like I did with my Big Head builds, I like to test my work by running it on high for as long as possible. With the resistor modded drivers, they only lasted for around 10 minutes. Each failure produced a very, very stinky burnt electronics smell. With one driver, one of its components split into two!

Well, at the moment I am running the light at medium and to see if that is ok.

No pictures for now, because I am not sure if this will be the final build.

As for the mods done:

- replaced the two R200 resistors for R100 and R120 to give a theoretical 5.3A to the LED

- replaced the wires on the driver for 22AWG

- copper braided the spring at the driver, along with the switch

  • used an XM-L2 T6 4C on a Noctigon MCPCB

I kept the dome on this one because I was trying to achieve maximum lumens on a single emitter, yet provide a good balance of throw and spill. I think I have achieved that here. It is being powered by King Kong INRs, but I also tried it with a pair of Panasonic NCR18650PF and it produced the same level of output.

The good news is that it is definitely brighter than my Big Head XM-L2 build when doing a ceiling bounce test and comparing the two by eye. Throw wise, I think the Big Head still wins out, but I need to get all my big lights outdoors to confirm this. The tint is also really good. The thermal path also seems to be working as it is heating up more quickly than either of my Big Head builds.

Now the bad news. A tailcap reading of 2.95A on King Kongs. Not too good, right? Also, when changing modes into medium and low, it produces a “pre-flash” similar to the typical Foursevens Quark Tactical line-up. It is a bit on the annoying side.

Will this replace my stolen Catapult v1? It is a good hitting stick, but I do not know if, after using it to hit someone, whether it will continue to light up or not (I didn’t do a good soldering job when changing the wires on the driver); it does not instil that same confidence of quality that the Catapult v1 had. Admittedly, it is brighter and throws better than it…so, let’s just say I am sitting on the fence for now.

2

Doesn't 2.95A in 2s configuration translate to roughly ~5.9A at the emitter?

3

Correct less efficiencies. Your next purchase will have to be a light meter. Is good to see that whoever had this light returned it at last. Slack bugger. :slight_smile:

4

After killing 3 Lightmalls “5A” drivers, 2 LD-29 drivers (I think one of they may still be working) and 1 XM-L2 T6 4C, I may have a functioning light now.

I used my final LD-29 driver and modded that with 2 R100 resistors stacked up on top of that. In doing this, I have lost medium or low mode in that, I now have what appears to be high, high then medium/low. It looks more of a medium than a low. The tail-cap current on a pair of KKs show a massive 6.5A at high and 1.8A at medium/low. Now, is that 6.5A true? Maybe… I do find the head heat up rapidly within ten seconds of turn on.

Oh, and I had to use the same XM-L2 as in my Big Head mod due to the T6 4C shorting out. It produces a very, very faint output now.

We’ll see how long this setup lasts.

5

…and I think I just killed my last known working LD-29 driver. There is that usual burnt electronics smell coming from the driver.

I may as well take a break from this light for a while. In the mean time, I think I will seriously consider ordering some of those ≧ 5A drivers so I don’t need to do any fiddling around myself. Also, during the break, there might be some new Noctigons that might come out, so I think I’ll hang back for now.

It is a great host with so much potential. Unfortunately, anything that I put in it, seems to keep on dying.

C’est la vie.