Jerommel's Hand Job 2018 - 6th annual BLF / Old Lumen Scratch Made Light Contest

Flashy_Mike · 2018-11-08T11:23:42.000Z

Yeah, this thin KD triple boards are crap. I ordered a couple of them way back with 219C mounted since they were pretty cheap but after mounting one of them into a S2+and the first LED dying quickly I never used them again.

Jerommel · 2018-11-08T12:43:56.000Z

Well, i should have flattened the board BEFORE i soldered the LEDs on to it, of course… :person_facepalming:
So i can only blame myself for this.
I knew they are not flat…

pinkpanda3310 · 2018-11-11T02:27:51.000Z

Kudos for your persistence. Also nice job lining up and cutting out a slot for the USB port :+1:

Jerommel · 2018-11-17T21:35:59.000Z

Well, it’s on hold at the moment…
There’s still that short in one of the LEDs (probably), so i finally put together my LED reflow device, consisting of the intestines of a thermostatic regulated soldering iron.
The heating element plus sensor (a ceramic rod with 4 wires coming out) i put in a large solid aluminium knob, so i would have a hot flat surface of about 40mm diameter.
And it worked! …for 15 minutes…
No idea what went wrong, but i chucked the whole thing in the bin…
And then the fluorescent tube light in the shed went out for the last time with a puff of smoke…
So i’m now replacing it with LEDs but also putting a 4 position switch regulator in the power line for the air extraction fan, which has been waiting for installation for quite a while too…
Much more work than anticipated, as usual…
And still no proper reflow thingy, which is a bit of a must for solder flowing 3030 LEDs on a triple 3535 board…

I will soon resume working on the light though.

…to be continued…

DavidEF · 2018-11-17T21:57:07.000Z

The element possibly burned out because it isn’t made for that kind of load (heating that whole knob). Or, maybe it was near failure anyway, and it just happened to give up while being used to reflow that time. Even if it was new, unused, it could have had poor tolerance or a manufacturing error. Still, a bum deal to have it go out, and the fluorescent tube as well. I hope you get back on track soon.

pinkpanda3310 · 2018-11-17T23:13:45.000Z

Aah, the joys of a man cave. To get to this you have to move that. And to finish making this you need to finish making that so you can use it to make this.

Good luck mate.

Jerommel · 2018-11-17T23:41:23.000Z

DavidEF:

The element possibly burned out because it isn’t made for that kind of load (heating that whole knob). Or, maybe it was near failure anyway, and it just happened to give up while being used to reflow that time. Even if it was new, unused, it could have had poor tolerance or a manufacturing error. Still, a bum deal to have it go out, and the fluorescent tube as well. :weary: I hope you get back on track soon.

I don’t think it was the heating coil.
I think the electronics decided to stop working.
There was a red LED on the PCB (which was originally in the handle of the soldering iron), and all seemwed fine, it heated up, it shut off and then a few times it went on and off, keeping the temperature stable, and then it went off for good…
It just died on me…
Managed to remove an XP-L from a LED board and that was all it ever did…

Oh well… Sh… happens.

I have the LEDs placed and working just now.
2 strips of 15x 5730 LEDs running an easy 5 Watts (0.33 Watt per LED) using 3S 600mA mains drivers, on 40cm lengths of aluminium curtain rail.
LEDs are 3000K (specified as 2700K but it’s a bit cooler) 95CRI Osram Duris E5 (new old stock) from a German Ebay vendor.
Nice lights.
Could do with some diffusing covers though…
Not really work lights, but for that i have a headlamp.
Nothing beats a good floody headlamp.

Funner · 2018-11-18T00:08:36.000Z

Cool

FmC · 2018-11-18T20:51:09.000Z

Several builds down to the wire this year for one reason or another - I hope you can get your build finished!

Jerommel · 2018-11-22T22:36:49.000Z

….aaaaaaannnndd i’m out of the ‘race’….

EVERYTHING went wrong…

All 3 LEDs were broken due to bending LED board, so i put on 3 new ones.
Problem solved, right?
Nope…
Something else must have gone wrong too, because i suddenly had only 1 mode Direct drive.
Yes, that would be the - minus making a short with the body.
And then the + wire broke off when investigating.
So, i had to get my pipe cutter to cut of the head, but the because of the epoxy potting i tore off some parts of the driver.
Soldered them back, but it didn’t work anymore…

All would have been well if i didn’t have broken and short circuiting LEDs from bending the LED board flat with a tap with a hammer on a rod placed in the centre of the board earlier…

Now it’s all for nothing, or at least, for this contest / build off.
Crap, crap, crap…

MRsDNF · 2018-11-22T22:47:32.000Z

I feel your frustration Jerommel. You showed us some amazing skills. Dont let it eat you up.

CRX · 2018-11-22T22:52:36.000Z

djozz · 2018-11-22T22:55:10.000Z

Still well done Jerommel! I did not even dare to start with a scratch build, while you did start and even came up with some really cool concepts!

Jerommel · 2018-11-22T23:00:45.000Z

@MRsDNF:

Yeah…

I still can’t believe the + wire just broke off…
It broke off where the wire couldn’t even bend, 3 to 4 mm inside the epoxy…

But oh well, it was very educational…
The battery with charger and switch in the tube still work, so i can put a new head on it eventually…
We’ll see…

Jerommel · 2018-11-22T22:59:30.000Z

djozz:

Still well done Jerommel! I did not even dare to start with a scratch build, while you did start and even came up with some really cool concepts! :+1:

Thanks Djozz.
Better luck next time.

MascaratumB · 2018-11-22T23:20:13.000Z

Hey, sorry to hear this
I was liking the concept and work!

Don’t lay your arms down, pick were you stopped and restart, even if it is not for the contest The time invested so far is much more than the one remaining to get a full working light

CheapThrills · 2018-11-22T23:20:19.000Z

Very oldskool, very cool 8)

pinkpanda3310 · 2018-11-23T00:48:53.000Z

Sorry to hear you’ve hit a wall. This is an amazing build so far. Would like to have seen the end product.

FmC · 2018-11-23T02:02:43.000Z

That sucks, but it was great to see what you had done

Maybe jam it back together & bypass the driver for direct drive?

MtnDon · 2018-11-23T04:04:26.000Z

Sorry for the bad luck…. dt