Somebody here in the forums said it could not be done. That it was impossible to create because the Cree XR-E die was too big. Etc. Etc.. There is nothing more exciting than trying out something that is supposed not to be possible
Edit: Here is the rest of the photos. I am not done adjusting the LED for optimum throw, but I am getting closer
As somebody below pointed out, I had to make a turbo module from scratch. I was able to make all operations from one side, except making the LED pedestal "flat":
I had to go back and make things "flat"
From left to right (EDIT: To clarify, I only made the last two on the right):
5W LED Luxeon Turbo Module, not yet used 5W LED Lusexon Turbo Module, First prototype of new Luxeon Turbo Module (a tad long so that I can play with it), even longer prototype of the Cree XR-E Turbo LED Module:
Of course the electronics cavity was designed around the converters from the Shoppe and the FluPIC:
The "key" to make this work is to file the Cree XR-E die while preserving enough to make the electrical connections:
Did I mentioned that making those connections was hard?
Here I am all done and testing it with just 150mA or so, outside the KT4 and inside the KT4:
I then used a Shoope Downboy 750 to complete the light, along with the outer spring from a blown P60 bulb and an inner spring from "something" in my workshop that happen to fit OK
Here are the beamshots. Please note that I am not yet done focusing the Cree yet. I made the post longer so that I can use shims to get it to the "sweet" spot, but that will take some additional time
First is the Cree XR-E at 750mA, at 2 seconds exposure:
Then the 5W Luxeon, at about 700mA, at 2 seconds exposure.
Same as above, but at 1 second exposure. First is the Cree XR-E then the 5W Luxeon:
Note on these shots above that the Cree has brighter sidebeam but that the 5W has a more intense hotspot. As I said above, I still need to play with the Cree to see what is the best I can achieve.
I then took some outdoor shots. In these it is easier to see the brighter sidebeam on the Cree.
First the Cree:
then the 5W Luxeon:
I will play some more this week to further focus the Cree to see what is the best it can be in this reflector