Love the looks, size, battery versatility and I mostly love the price of this flashlight. Selling at $14, I had to have it. But it is a zoomie and I’d have to stretch it very far to say that it is a good one.
I had no interest in this flashlight as a zoomie and then my brain started to work overtime. Last few months was all high CRI Nichia here on BLF so I had to use these fine Led’s and work something out. This time I managed to keep everything at the budget side.
So let’s start and see if you like this mod as much as I do.
Project cost:
1. Warsun X50 - $13,39 (Banggood)
2. Triple Nichia 219C (4000k) 90 CRI - $7,87 (Kaidomain)
3. 3 x 16 mm XP MCPCB - $4,47 (Kaidomain)
4. LD-3 9A driver - $15,00 (Led4Power)
5. TIR optics from Ledil - $10,00 (Local web store)
6. Copper, switch, boot, wires, etc. - $10,00
1. Warsun X50
2. Disassembled. Bad design. Lightweight and hollow pill. One MCPCB on top of the other MCPCB. Pill is not making any contact with the body of the flashlight. I’ll have to completely rework this to improve heatsinking.
3. Switch mod parts. Only thing that is worth is the omten switch.
4. I managed to ruin the threads on the original switch retaining ring (very thin and soft aluminum). Luckily, I had one old Ultrafire flashlight that had the same threads at its brass drivers pill.
5.Brass driver pill cut, sanded and reworked into a retaining ring for my Warsun.
6. Almost done.
7. Switch mod complete.
8. Hope this omten can take 9 Amps.
9. Switch tightened. The threads are holding. Looking good.
10. Drivers pill mod parts. I reused the bottom part of the Ultrafire pill to hold the 17mm LD-3 driver.
11. Stripped driver’s PCB, brass ring and copper plate mash-up.
12. Driver’s pill done.
13. Other side.
14. In its place.
15. Aluminum pill top is cut.
16. Made a 3mm aluminum plate to fill the void.
17. Aluminum plate brazed from the inside.
18. Top sanded and finished. Stage one complete.
19. Copper ring cut to fit inside the flashlight body.
20. Tight fit. At this point I realized that battery tube fits inside the copper ring.
21. So I made a bigger ring.
22. Cut and reworked to fit.
23. Another tight fit.
24. Bottom side. Copper ring all the way in. The “step” inside the flashlight head stops the ring to go any further.
25. Top side. I made one copper plate. It sits on a battery tube below.
26. Big copper rod chunk, courtesy of kiriba-ru, received few weeks ago. It is time to put it in good use.
27. Pill parts cut and sanded to fit.
28. Everything soldered. Hope I can pull it out of the head.
29. Cleaned and sanded.
30. Other side.
31. Pill drilled, threaded, sanded and polished.
32. Aluminum pill bolted inside the copper pill.
33. Battery tube screwed between two pill’s.
34. Inside the head. This turned out very nice. Executed like this, majority of the heat from led’s should sink properly trough the head instead trough the battery tube.
35. MCPCB’s cut to fit inside. Also made a triangle holder for TIR optics. It is the same height as those MCPCB’s. That is going to ensure the correct distance between the led’s and TIR optics. Convoy L6 centering rings are there to help me center little Nichias. I’ll remove them later.
36. MCPCB’s fixed with arctic alumina epoxy.
37. Inside the head.
38. Driver wired. Ground wire bolted.
39. Nichias wired.
40. Battery tube along with the pill are not fixed to the head of the flashlight. Had two solutions for this problem - gluing or bolting. I like flashlights that can be disassembled (for servicing purposes if needed) so I chose bolts.
41. Final touch. I had to do it.
42. Now it is done!
43. Three eyed Warsun.
44. Tailcap decoration. Pill bolts painted mat black.
45. To get the perception of the size. From left to right - Convoy S8, Warsun X50, Jaxman X1, Brynite B158 and ZY-T08 Small Sun.
46. Glow in the dark tape inside the head.
Tailcap measurements (26650):
Moon - 0.01A
Low 1 - 0.13A
Low 2 - 0.64A
Med - 1.62A
High - 3.14A
Turbo - 8.95A
As you can see, everything worked out great although I wasn’t sure I could finish this one. It was a struggle all the way. But the reward is another beautiful performer. You can run this puppy hard, heatsinking works pretty good. 26650, 18650, 3xAA, the choice is yours. Love it!
I’ll try to make some beashots tomorrow, of to bed now.
Did you like my newest mod? Please comment.
Cheers
.
