Your ~1200ma GD driver is holding up well? Does it have many hours on it? Did you heatsink it?
Sorry, Greg for the late reply, forgot & missed this I guess.
I personally did not put a heavy amount of hours on it but I did test it & use it fairly enough I would say. I fully potted the board, not sure how hot the board actually gets though. Never heard any issues with it. YMMV though & again, I don't think Wayne would approve driving it that high.
What did you use to pot those stacks? How did you keep everything parallel during assembly/soldering? What are those vertical standoff/conductors made of -- tinned solid conductor from some hookup wire with insulation removed? I was considering using some 24 gauge copper hookup wire.
For the SOB stack, how are you bringing the power from the LED+ and LED- posts to the emitter? Do you have plug-in connectors that attach to the LED+ and LED- posts? Otherwise, I would have thought that it would be better to solder in two wires for the topmost SOB board at LED+ and LED- and run the wires to the emitter. I assume that you have Conductor1 passing through each of the GND holes of the SOBs, Conductor2 passing through the matching LED- holes at J6, Conductor3 passing through the matching LED+ holes at J5, and Conductor4 passing through each of the Vin holes of the SOBs. Then I assume you soldered a post to the remaining open LED- hole on the top SOB board and another post to the remaining open LED+ hole on the top SOB board.
I used Devcon mixed with alumina oxide powder to pot these. You can use other stuff to pot though too.
Yes, the vertical conductors is just the same ol 26 awg stranded wire that I use for most of my builds. Removed the insulation & tinned the wires before assembly. I soldered on all the uninsulated tinned wires to the bottom board first. Then I slid the next board on till it rests against the inductor of the bottom board. Soldered the connections, then slid on the next board (with the GD stack). After that I potted it.
From the excess tinned wires joining the boards or the posts as it appears, I just soldered wires directly to them. I never use connectors with drivers & I highly recommend not using any either.
You are right again. I've got four wires passing through each matching hole joining the boards. The ground & Vin wires are cut short at the top. At the bottom I left enough wires for the ground just as I did on the top to make the ground connection.
This was fun & they work great but you may just want to wait a bit. Wayne has a
SOB3A in the works.