Modding Plastic HOST to Thrower !!! More pics and some progress

Flashlight Modding and DIY Parts
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Hi every one

I had an old plastic Coleman flashlight that had a very nice SMO reflector 71mm(D) x 55.5mm ( H ) well i wanted to use this reflector to build a thrower but didnt find any of my flash lights would fit with it so i had this crazy thought to mod this plastic host, well i had the challenge for a long time, but really how would i do it ? at 1st i thought to take the head and fit it with 2D mag body i tried to fit them and they would fit together but where is the fun and i may face heat problems and someday i got this Idea Lets see pics will tell

The Host

When opened to work as lantern

Dirty lens will be polished later

Head disassembled

Reflector

Reflector filed to fit the focus of the led that took so much time try and error.

And now the heatsink and the modding parts.

CPU Heatsink with a big chunk of copper, i think Intel uses a good copper.

The copper heart were taken out by a hydraulic presses.

Now modding the heatsink relax everything is coming.

The copper pill were machined to make a place for the led and made two holes for the wires.

Now modding the plastic host i made a place for the heatsink.

heatsink were assembled in the body .

Now getting everything together.

Finally the challenge were Done .

I am lucky the reflector fits GREAT with the Pill .

I have a big room i can put 4 18650 cells and a big Driver.

Rest is easy led , driver , switch now i am thinking how i will put the cells i may think to use a cells pack .

Sorry for the bad phone pics

To Be continued …

this host beside small sun ZYT-08

I decided to use a dedomed XM-L2 1A running at 6A, now the led dedomed and mounted

I used the driver TR-0124B from FT modded with the Trimpot

thanks for ImA4Wheelr and RaceR86

Head mounted

I made a side switch

Reflector and lens cleaned

It is hard to make a place for the cells for easy changing so i had to make a battery pack it is 2b2s and as temporary i will solder them directly to the switch and the driver tell i figure something else

Now it’s ready

i will try to post some beam shots as long as i have them

thanks for watching

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Subscribed

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Cool mod :slight_smile: i have a similar yellow Eveready version of that light with the slide-up lantern mode.

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Wow!

Awesome mod! I love how the copper core of the heatsink became your copper pill.

The heatsink and pill looks pretty huge. Should be plenty cool to keep your XML2 from melting. But I think if you ran an MTG2 at high amps, the plastic heatsink mount might melt.

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Sweet!

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More pics and some progress in the OP

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This is certainly one outside the square. I love your ingenuity. Well done.

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some out door beam shots i know its late but i waited to buy a good camera i bought Canon SX50 HS but i still need to learn how to take pics

this photo were taken from the roof aiming at a new building that no one is living there now its about 185 meters away .

control

Zoomed a little bit

zoomed more

as long as i am still learning how to shot with this camera pics are not the best well the beam shots is much brighter in the real life

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That is actually impressively focused for a LED in a Reflector designed originally for a Incandescent bulb. :slight_smile: nice work. This gives me hope i can mod the one i have that is similar to yours to make irt a compact thrower.

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I am still reading.
My approach was liquid cooling, but I don’t have a usable light to show success.

Is the copper pill stuck back into the Al heat sink far enough to transfer heat?

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+1 to what DenBarretSar said. I would not have guessed from the beamshot that the reflector was not originally a led refflector. Well done!

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Yes but i used some thermal past to ensure the heat transfer