Re: CMG Infinity Mod.....Lots of Pictures!!
Will, thanks again for the pics.
First I have to say "Please excuse me my poor English." I need to take some ESL class.
I intended to make the post after I had my mod done. But as seeing so many posts on coming, I changed my mind to share some of my experience before that(becaus I don't know when I can have it done).
1) In order to remove the circuit board out of the bezel, after triming the rolling edge, we can put the head of the Infinity(not yours) into some boiling water(I read this somewhere in this forum, can't find it again). In this way, we never worry the components are overheated. After a couple of minute, we can try to apply force to the LED to pushing it out from the bezel. If it is still too firm, replace the water with some fresh boiled and try again.
2) To remove the epoxy, again we put the circuit board into some boiling water, use a small paint brush, brushing, twisting and rotating the brush on the circuit board and the components. The epoxy would stick onto the brush and make the brush sticky and can't go on cleaning. Put the brush into some isopropyl rubbing alcohol, the epoxy would dissolve very fast and the brush returns clean and is ready to use again. Repeatly the use of boiling water and brush the circuit board until the epoxy is completely removed(don't put your fingers into the water, it is boiling hot).
3) As koala(CPF member) mentioned on his post, the circuit board is a Zetex circuit board. He removed the resistor and replaced with a 32 ga. wire and drived the 1 watt LS with this circuit. After reading his post and links, I soldered the wire without removing the resistor to save some work(it made no difference to resistance) and the effect was so good. I compared it with the flashlights I had on hand. With 1 fresh AA cell, CMG Infinity mod circuit board, NX50 optic, it was out and away the brightness of the Infinity Ultra Government and Tekna Splash-Lite 1 CR123, and was about the same of the Streamlight TwinTask 2D, 5 LED. I then supplied the power with a CR123(yes, 3 volt), it won the Streamlight TT 2D, 10 LED by a long shot and probably was the same or 95% as the Lamda Ill Pill, 1 CR123. Be careful with your fingers again, the emitter is burning hot.
4) One thing worths to try out is to replace the inductor. On the Zetex website, there is a new circuit to drive 1W LED with the ZXS310. The recommanded inductor is Coilcraft DO3316P-223. From Coilcraft, I get the spec. 22uH, DCR 0.085 Ohm, Isat 2.6A. Also from Zetex, I have an old circuit diagram, which I believe is used in the Infinity, of the ZXS300 to drive a bright LED. The recommanded inductor is DO1608P-104, which is 100uH, DCR 0.48 Ohm and Isat 0.13A. If I am correct then the coil on the circuit board is far below the LS needs. The Digi-Key doesn't have the Coilcraft. I am looking for a substitute. I know Digi-Key is selling some other make. But I would like to test my handmade coil first. I have some ferrite bead from Digi-Key only D 3.30mm, L 5.74mm(0.236"). I made a coil and it works fine on an Ill Pill replacing the comparative huge toroid coil.
5) One thing koala mentioned about was that the LS could not start up when the voltage was below 1.2V(AA alka) in his mod due to the demand of high current by the LS. But in my mod(circuit only), I can start up the LS with an almost dry out AA alk(burnt 8+ hr in an Infinity G and some burnt of the LS with the mod circuit). The brightness is dim though, about half of the Infinity G. with fresh battery, but I don't know how long it can last.
I don't have adequate tools at present, not even have a multimeter. But I've just ordered some, once I get them I will do the measuring of current and voltage. But one thing I am sure now is that my though at the very beginning is completely right. We can have the minimum cost to modify the Infinity with best result. According to the ZXSC300 spec., we can drive the circuit with voltage from 0.8V to 8V. With the form factor of the Infinity, we can use 1 AA alk or L, 1 CR2, all depend on your need-cheap battery, longevity of in shelf reserve or maximum brightness. Might be we can drive a 5W LS with 2 CR2, or use the AA L 3.6V to fit any LS. I will do the experiments in the future(I just made a test drive the 1W LS with 2 CR123, 6V!!!. It was incredible bright. But I just connected for a couple of second, no heatsink yet, I didn't want it burnt).
The Infinity is superio to the other lights to mod is that its low cost, $11 to $15, and we don't even need to spend a dime on the circuit board. Compare with the others, they not only cost some money but can't start up with 1 cell. Some circuits are of 1 cell, but they are so dim. The Infinity board can drive the LS from a single AA cell to 2 CR2(need to measure the Vout and Iout).
I am glad to see some knowledge people here can do the above mentioned mod and share the experience with us. And I have to say thanks to darkzero and koala. They both gave me a lot of ideas and experience in their posts.