New build. Monster 9 amp MTG-2 or bust. Updated post 66, 21.1.14

After the disappointment of the DST 9 amp light, which has been very happy running at 5 amps, I decided to build a light from the ground up with the sole intention of having a flashlight running the MTG-2 led reliably at 9 amps. This is a work in progress so I don't know if I've achieved my wish or busted. Already I have had one component busted, my lathe. I'll explain later. To date all the machine work has been completed and all components are in my hot little hands except the three 32650 batteries from FT. The only thing really stopping this light working is some soldering. I'm not sure how to tackle it yet. Lets get into it.

I purchased a lump of aluminium which started life 90mm round x 150mm long. It took a couple of weekends to machine this down to size due to slipping V belts and lack of rigidity but we eventually got there. The 150mm was kept as long as possible while the outside diameter ended up at 80mm to suit the lens.

Knurling is really tough on my lathe as it just is not rigid enough. The following knurl resulted in the picture below it.

Looking from the reflector end of the housing you can sort of see the inside machined to fit the reflector and pill. The pill threads in from this side while the usable diameter of the reflector is 68mm. I will include links and pictures of the other components at a later date.

The pill did not get of to a very good start as the thread picked up big time when it was nearly onsize and a 1/8'' drill bit decided to break of in it. Its not coming out either. The thread cleaned up reasonably well but looks terrible on the macro shots.

The bezel was machined from an offcut of aluminium bar.

Madness had by now set in as even though I had copper stars I wanted the led mounted directly to the copper pill. On a brief test it works. Touch wood.

To make sure of a good earth from the battery to the flashlight body a 3/4'' BSP brass plug was scrounged and machined into a boss to screw into the tailcap. An o'ring is there to keep the crud out. The boss is hollowed out on the outside as this was the original hollow in the plug which has been cleaned up.

The tailcap in all its glory. The cap screws are 3mm. Diameter is 48mm.

The bezel holds the lens as its a smaller diameter than the outside diameter of the reflector with an o'ring between it and the housing. Cap screws are again 3mm.

The switch was a bit of a challenge. The switch itself (thanks Mr Duck) needs to be inserted in position while the white sleeve is inserted. The board with the flexible wire attached is then pressed into its recess with the wire tucked into the groove under the switch. Its not ideal but should work ok.

The battery tube swallows the 26650 battery tube from my MTG-2 DST.

The head is pretty massive. 150mm long x 80mm in diameter. The switch area is 48mm in diameter.

The pedestal the head is leaning on is the standard defiant super thrower heatsink.

Finally a couple of pictures for comparison of the size. Left is a MagLite 3C and right is a DST 3 x 26650.

And finally, left a C12 and right a standard DST.

The following is a few links to the components used. I would like to take the time to thank the members here who sent me parts an advise on some of the parts to use.

The lens came from ebay. It was a 74mm massa multi coated lens. I wasn't sure what I would end up with but it turned out to be nicely coated and 2mm thick.

The reflector came from DX. I have read reports that some members have received poor ones. The one I received was fine. It is advertised as being for an SST-90 led.

The rubber switch boot came from FT. The rubber nub was cut to length to suit the switch.

The switch is a 10 amp Judco which was sent over by a member here. l'm not sure which one it is.

The driver came from LckLed and did not work. It worked fine on a XML before the 9 amps killed it in a millionth of a second. With the MTG-2 it would only operate on low. It did not matter what voltage was fed to it from a bench power supply. The light has been fitted with the IOS driver that has its own problems but it is up and running.

This is a close up of the led and isolator. It was machined from a piece of 25mm black plastic or teflon that was kicking around and so far has not melted. The step for the reflector is 1mm in depth with an overall thickness of about 2.5mm. The reflector does have a very few minor imperfections around the led opening but I don't believe it will affect the beam at all.

A few different shots of the assembled light. With 26650 Trustfire batteries installed all up weight is 3.5Kg. This will be slightly higher whenever I can get 32650 batteries.

The next couple of pictures are with the HD2010 for a size comparison of the reflector size.

Finally for now is a comparison of different reflectors with MTG-2 leds. A shootout will be coming soon.
Left to right, top to bottom. OL Maglite custom build. Defiant 3C Armor Max. Defiant 3C super Thrower. This light.
The following night shots are not to show the brightest light as all these lights all have different drivers, but more to show the effect of different reflectors on the MTG-2 led. All pictures are a lot darker than they appear in real life to better show the hot spot of each light.
Firstly is the stock HD2010 for a comparison with a XML-2 led in a common light.
Stock standard Trustfire TR-3T6. My only multi emitter light.

OL Maglite MTG-2.

Defiant 3C Armor Max MTG-2.

Defiant 3C Super Thrower MTG-2.

DX reflector MTG-2. This reflector has the most conventional light pattern of all the different lights here. It has a very distinct hot spot.
Mouse over. DST. Mouse over this light.
Thats it for now. l did not really achieve what I set out to do but I'm happy with the reflector. It almost turns this led into a thrower. I'll use it the way it is for the time being and maybe, who knows, this may very well end up with a 5 amp driver in it as well. IOS does not stock my favorite driver anymore so the hunt is on for another.
Thanks for reading.
I've just added some sling mounts to the light and while it was apart I took a shot of the isolator.
And a couple of shots of the sling and mounts. I bought two slings awhile ago for a couple of dollars each. I believe they originally come from a picnic basket. The mounts themselves were made from a piece of 6mm flat aluminium and are about 20mm in height. The cap screws holding them on are 3mm.

Wow.. does it come with a trolley? ;)

How much does that thing weigh?

The empty shell weighs 2 pound or 900 grams. Fully loaded I may have to use the wheelbarrow to transport it.

whahaha.. nice!

Now you need to make a special shoulder strap for it! ;)

Anyway, looking forward to some (comparison) beamshots when its done.

It is beautiful! And what a work to make all those pieces with a lathe that does not cooperate . I hope you get the electronics right and get the full 9 amps reliably through the led.

Fantastic work!

Can’t be bothered to make your own batteries? For shame! :stuck_out_tongue:

It looks amazing, great job!

I so love it when you create. Looks fantastic. So husky and elegant at the same time.

Outstanding Steve! Looks great, a behemoth of a light as befits the MT-G2 in Turbo mode. Even all that probably won’t be enough in the end, but it’s going to work and work well. Search and rescue with the added benefit of an annihilation factor built in if you ever run into the bad guys. :wink:

The weight, come on guys, really? Must be a lot of mice out there. My camera body weighs 3 lbs. My favorite lens on it weighs another 2 lbs., and then there’s the flash with 4AA, flash bracket , hot shoe cord….almost 8 lbs of camera than I can hold one handed while running focus and zoom with the other. Granted, a 14 hour day gets grueling. But holding the body of a camera vertical with the torque of a 2 lb lens out front is really not comparable to holding the tube of a light, even if it weighed 10 lbs it’d be relatively easy to hold and keep steady by it’s simple design parameter.

Cowboy Up!

Would love to be able to take THIS one off your hands, cool light, excellent extraction of the physical from the idea.
Big thumbs up from me, nice to see you back in the saddle…

Very nice work. Looks really great. Wow!
I know I have seen that homemade sink pad thing somewhere. :bigsmile:

You might be a pioneer, but a good design won’t be held down…this will be in production lights before you know it! :wink:

That’s impressive work you have done there.

Group buy anyone? :stuck_out_tongue: (just kidding)

Beautiful light. I’ve always enjoyed checking out all the these lights you make out of bare aluminum. I truly wish manufacturers would put out some lights like that. Perhaps with a clear anodizing, I assume that’s possible???
Anyway, love your work and will be filling this thread.


OMG, that is a friggin Monster! That could double as a baseball bat. Definitely if you can't blind 'em with it, you can beat 'em with it!Tongue Out

That really is some nice knurling, even with all the problems you had with the lathe.

What kind of driver is going in that thing? Hmmm...

Really is different and some nice work done there.

Good to see you are back at it again and among the living again.Wink

Just amazing! Can’t wait to see it in action. Have you found a way of making the 9Amp IO driver co-operate for this build or is something else being used for a driver?

Oh how I admire your talent! Outstanding work as usual. Really looking forward to seeing this monster light up. 8)

Hey JohnnyMac, don’t you think Steve’s gonna need to run video when he fires it up? That way we can hear the hum of power as it destroys the night! :slight_smile:

Might have to keep the video camera a good distance away though, as this behemoth might leech power from every device within 30’.

Wow, double Wow. Never had envy eat my soul, but this is getting pretty hard to control. Good work, always wanted to be able to be a machinist, but will never happen. Kudos to you, you make us all proud and envious … ha … :wink: :bigsmile:

Excellent machine work. I too share your machine woes. My motor died 2 days ago and is at the shop getting repaired now.