Solder joints blocking reflector, will this affect my throw?

Where should my dedomed emitter be placed for the best focus? My board is too small so the solder joints does not allow my reflector fit perfectly on the board.
Right now my reflector is a little above the emitter because of the solder joints.

Can someone tell me what is the best configuration for the emitter to be at? 1, 2, or 3?

If it has to be lower, I might cut my reflector so it can fit. Or buy a 20mm star. The reflector is already 16mm, 4mm room wouldnt really help me much here tho…
any suggestions? thanks!

Too much solder, not hot enough, single strand wire?

Maybe the flat battery tab strips could be used, then cover with Kaptan tape. Mind the edges don't short to star edge. Still may need filing down the base of the reflector.

Yes, flat tabs would be best Only adds about 0.1mm, if you do it properly.
It’s a common problem though…

FT has good Kapton tape.

Old Lumens actually got strips of copper and extended the pads to sides like wings to get the wires away from the reflector on one of his builds

Just be careful to insulate them well…I recommend liquid electrical tape in that case in order to provide proper protection and ease of application

Solution…unsolder, place some electrical tape on the sides of the star over the copper slug, get some very thin copper strips, solder to the star, solder the wires to the strips, cover with liquid electrical tape (since it will be hidden behind the reflector) then reassemble

wow, strips of copper! I HAVE, and this kapton tape… way better than my electrical tape!!!
thanks guys, you really helped me out here.

I think you should have began with a 20mm MCPCB to start with.

Yeah that sure would have moved out the solder joints for sure :wink:

The copper tabs works like a charm! thanks!

now to wait 2 weeks for some kapton tape ;D

Kapton tape is one of the great inventions done for the flashlight modder.

I love Kapton tape!

Got my roll from Mountain Electronics I think.