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Thread: DIY for Barbolight Bomb-Proof Host with MC-E and McR45 ...

  1. #1
    *Flashaholic* wquiles's Avatar
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    Default DIY for Barbolight Bomb-Proof Host with MC-E and McR45 ...

    On my last Barbo host project, I used a P7 and a P7 reflector:
    http://www.candlepowerforums.com/vb/...d.php?t=222258


    For this one, the owner wanted to use the MC-E, and the very hard to find McGizmo 45mm reflector (McR45):



    As with many of these projects, this is a combination never tried before, so I was not sure how it was going to work until the very end. Lets get started ...

    Like before, I need to make a large hole in the head (where the built-in heatsink is located) since the reflector is very deep - in fact, this reflector sits significantly deeper than the P7 I used earlier:





    As you can see here, I still need to cut more, as it is not yet flush with the lens groove:





    Not only do you need to cut in the head, but the reflector itself has to also be trimmed since a good portion resides inside the main body:









    And after many cut-and-tries, it finally fits:



    Now, lets deal with the MC-E. Unlike the P7, the LED and the LED dome are smaller, so I can't use the reflector to center the LED:



    To provide a really good and strong mounting to the heatsink, I decided to use a "star":



    With my new bench pin-vise (thanks to forum member darkzero), I proceeded to solder the emiter in place:





    First clean emiter and star:



    Then apply thermal paste. I am not using epoxy, since the emiter will be soldered at 8 points - that should be enough





    Now that I had the emiter on the star, I started playing with the focus, only to find that it was not focusing well (the McR45 is the best LED reflector I have ever used, but it was not designed for the MC-E!). So I had to raise the emiter, slowly, by trimming from the reflector in light pases - needless to say, this took a LONG time:



    I then cleaned the edge of the main tube for a good electrical contact:



    And then proceeded to create from scratch a new heatsink. Note that in trying to make a simpler assembly, I am no longer using a threaded heatsink. I will be using a press fit heatsink, with a hidden set screw to still guarantee a "bomb proof" design













    I then milled a pocket for the positive contact/spring assembly - can you tell where it comes from?:







    Here is the assembled heatsink/emiter/plug:



    For the positive contact I made a hole all through the heatsink, and for the negative, I threaded a small blind hole:





    Now that I am ready to get the emiter epoxied to the heatsink, I need a way to center it, so I made a delrin centering "adapter":







    Prepare the epoxy:



    get it inside the tube:



    place adapter in place, gently rotating it to get the emiter centered:



    and momentarily apply light pressure to seat the emiter in place:



    Here I am drilling and tapping the body and the emiter, once I figured out the right position inside the body:







    Then solder the wires on top:



    and get the spring ready in the bottom:





    Epoxy the plastic base, spring, and wire in place:



    Apply krapton tape to prevent a short from emiter and reflector:



    Apply a light coat of thermal epoxy to the "plug":



    Apply high-temp silicone to keep the reflector in place:



    And finally put the battery and see if this contraption works!:



    EDIT: just took some beamshots. Fujifilm Finepix S100FS, on tripod, on manual mode (F2.8 @ 2sec), lens set to full wide angle. Both the 18650 cell in the P7 and the A123 in the MC-E are charged.

    1) First WQ Barbo Host with P7, then WQ Barbo Host with MC-E/McR45:




    2) First WQ Barbo Host with P7, then WQ Barbo Host with MC-E/McR45:




    3) First WQ Barbo Host with P7, then WQ Barbo Host with MC-E/McR45:




    You can see the P7 reflector giving a wider coverage, but the McR45 has more throw and a narrower beam. You can also barely see a little bit of the donut hole in the McR45 reflector, just like with the older 5W Luxeons, but it is not very noticeable.

    Will
    Last edited by wquiles; 03-20-2009 at 06:37 PM.

  2. #2
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    Default Re: DIY for Barbolight Bomb-Proof Host with MC-E and McR45 ...

    WOW!

    I can't wait to see what this beam looks like!

  3. #3
    Flashaholic* cryhavok's Avatar
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    Default Re: DIY for Barbolight Bomb-Proof Host with MC-E and McR45 ...

    Sweet!!

    I wonder how this one compares in throw to your P7 mod...any comments before the beamshots?

  4. #4
    *Flashaholic* wquiles's Avatar
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    Default Re: DIY for Barbolight Bomb-Proof Host with MC-E and McR45 ...

    Quote Originally Posted by donn_ View Post
    WOW!

    I can't wait to see what this beam looks like!
    Quote Originally Posted by cryhavok View Post
    Sweet!!

    I wonder how this one compares in throw to your P7 mod...any comments before the beamshots?

    Just posted the pics, and in fact I decided to compare my two Barbo builds

    Will

  5. #5

    Default Re: DIY for Barbolight Bomb-Proof Host with MC-E and McR45 ...

    Oh my! Beautiful build and pics.


    The beam on the cut down mcr-45 is impressive!

    Whats the current draw on the MC-E a123 combo?
    Last edited by MWClint; 03-20-2009 at 06:50 PM.

  6. #6
    Flashaholic* cryhavok's Avatar
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    Default Re: DIY for Barbolight Bomb-Proof Host with MC-E and McR45 ...

    Awesome work!

    I'm glad one of those rare McR45s were able to be put to work!


  7. #7
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    Default Re: DIY for Barbolight Bomb-Proof Host with MC-E and McR45 ...

    Wonderful write-up Will!
    Kind Regards

    David

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    Default Re: DIY for Barbolight Bomb-Proof Host with MC-E and McR45 ...

    Quote Originally Posted by donn_ View Post
    WOW!

    I can't wait to see what this beam looks like!
    WOW again! What a great looking beam!

  9. #9
    Flashaholic* cnjl3's Avatar
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    Default Re: DIY for Barbolight Bomb-Proof Host with MC-E and McR45 ...

    Both your P7 and now this MC-E build look just Awesome. You are producing fantastic builds. I find it amusing that both threads are titled as 'DIY' projects but I would guess that most CPF-ers do not own expensive machine shop type lathe & mill. Yes, I am just jealous of your toys and skill level. I really enjoy looking at your step-by-step projects. You make this hobby fun. Keep up the good work.


    Carlos

  10. #10
    *Flashaholic* wquiles's Avatar
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    Default Re: DIY for Barbolight Bomb-Proof Host with MC-E and McR45 ...

    Thanks guys


    Quote Originally Posted by cnjl3 View Post
    Both your P7 and now this MC-E build look just Awesome. You are producing fantastic builds. I find it amusing that both threads are titled as 'DIY' projects but I would guess that most CPF-ers do not own expensive machine shop type lathe & mill. Yes, I am just jealous of your toys and skill level. I really enjoy looking at your step-by-step projects. You make this hobby fun. Keep up the good work.


    Carlos
    When I started in this hobby and I looked the finished products/projects, I always wondered "how" it was put together. A few people actually posted how they did theirs, and even if I did not had the tools to build them back then, it game me a better appretiation for the time and factors/considerations that the builder took to make his/her project. It also gave me the confidence to say to myself: "You know, I could build something like that as well". That is my motivation to my posts, which have TONS of pictures and step-by-step details as to how I did it.

    This particular light took me between 7-8 hours to complete, and I literally spent all day Friday making it (I was on vacation from my day job on Friday). Since I sold my mini-mill a week ago and since my new-to-me knee-mill is not yet running, I had to do all my drilling/tapping the old fashion way - by hand. So except for the lathe, everything else can be duplicated by hand tools, a soldering iron, patience, and attention to detail. Maybe the DIY moniker is a little bit of a stretch, but if you have a lathe that can hold a 2.3" diameter head, you can do it too

    And if you don't have a lathe yet, this project is yet another excuse to get one

    Will

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    Flashaholic* olrac's Avatar
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    Default Re: DIY for Barbolight Bomb-Proof Host with MC-E and McR45 ...

    Nice clean build Will it's making me think about buying a lathe

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    Default Re: DIY for Barbolight Bomb-Proof Host with MC-E and McR45 ...

    Couldn't help but notice the small fortune of tool post holders you have on the bench. That would certainly help on the old setup problems I have!!

    I finally broke down last month and got about 5 more so I don't have to change crap around. Life much easier now...

    I will add too, that your pictures are worth a million bucks. Nice to learn techniques from someone else!!

    Bob E.
    TF 3W Lux,TF 3 W Cree,Fenix L2D-CE, Fenix L2T,Fenix P1D,Fenix P3D-CE w/3x123 tactical body,P3D-CE Q5 w/2x123 tact bdy,3D & 3C Mag w/Malkoff,Modded ROV Swivel Sportsman with KPR112 bulb & 3xCR123

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    Flashaholic* Barbarin's Avatar
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    Default Re: DIY for Barbolight Bomb-Proof Host with MC-E and McR45 ...

    An impressive job, doing it and documenting it.

    I'm sure Will is going to have some hosts to play with very soon. We are working on a new reflector for P7's and MC-E's (yes, fits both), a little bit deeper than the previous which will increase lux reading at spot by 50% at least if not 100%.

    Javier
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  14. #14

    Default Re: DIY for Barbolight Bomb-Proof Host with MC-E and McR45 ...

    Nice build! Whats the silicon for???

    Mac
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    *Flashaholic* wquiles's Avatar
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    Default Re: DIY for Barbolight Bomb-Proof Host with MC-E and McR45 ...

    Ahh - the silicone. The reflector is press-fit to the main tube, but it has a few mills of space between the reflector and the bottom of the head. Using silicone there makes sure that the reflector will not move, plus, when diving, as the lens flexes, the silicon will take a little bit of this movement

    Will

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    Default Re: DIY for Barbolight Bomb-Proof Host with MC-E and McR45 ...

    Are you really supposed to use thermal paste under the LED between it and the star?

    I have read it should only be solder for good heat transfer.

  17. #17
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    Default Re: DIY for Barbolight Bomb-Proof Host with MC-E and McR45 ...

    Great build & nice pictures as always!
    -Will-

    Sorry, I have retired from flashlight modding, I do not offer machining services, & I do not make custom flashlights. Thank you for your understanding.

    My Mod Archive

  18. #18

    Default Re: DIY for Barbolight Bomb-Proof Host with MC-E and McR45 ...

    Quote Originally Posted by kuksul08 View Post
    Are you really supposed to use thermal paste under the LED between it and the star?

    I have read it should only be solder for good heat transfer.
    Many people use thermal paste or epoxy and have had no issues.

    Mac
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  19. #19
    *Flashaholic* wquiles's Avatar
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    Default Re: DIY for Barbolight Bomb-Proof Host with MC-E and McR45 ...

    Quote Originally Posted by cmacclel View Post
    Many people use thermal paste or epoxy and have had no issues.

    Mac
    +1. If you have wave soldering or an oven, yes, soldering to the star would be even better, but we have been successfully using the thermal paste + soldering pins (like I did), or the 2-part thermal epoxy (probably the most common) for many years with outstanding results

    Will
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    Default Re: DIY for Barbolight Bomb-Proof Host with MC-E and McR45 ...

    Ok...this is my new favorite light. Not only is it a great looking host, but Will's build is exquisite! The beam from the McR45 is nothing short of amazing. Within 5' of the wall, it's perfect. Further out, there's a barely noticeable center blur. 45' away, I can't see it at all. I doubt if it'll be visible in actual use outdoors.




    (Click to enlarge)

    I've run it on the A123 it was designed for, an AW C and a 26670 Emoli. It's brightest on the Emoli, but not enough to put up with the much longer charge time.

    Great job, Will! This is a masterpiece!

  21. #21
    *Flashaholic* wquiles's Avatar
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    Default Re: DIY for Barbolight Bomb-Proof Host with MC-E and McR45 ...

    Thank you Donn for the kind words

    You still get full credit for the idea for this project: Barbo Host + McR45 reflector + MC-E = great combo

    Will
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    *Flashaholic* precisionworks's Avatar
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    Default Re: DIY for Barbolight Bomb-Proof Host with MC-E and McR45 ...

    Very nice job

    The P7 is my favorite emitter, when you want lots of lumens plus a lot of flood.
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  23. #23

    Default Re: DIY for Barbolight Bomb-Proof Host with MC-E and McR45 ...

    Hi Will,


    Great build and effort especially on the documentation.



    With regards,
    Jo @ Britelumens

  24. #24
    *Flashaholic* wquiles's Avatar
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    Default Re: DIY for Barbolight Bomb-Proof Host with MC-E and McR45 ...

    Thank you Barry and Jo

    Will
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    Default Re: DIY for Barbolight Bomb-Proof Host with MC-E and McR45 ...

    Fantastic work - a superb build, producing a very impressive beam pattern. Another great tutorial thread - many thanks!
    Resistance is futile...

  26. #26
    *Flashaholic* wquiles's Avatar
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    Default Re: DIY for Barbolight Bomb-Proof Host with MC-E and McR45 ...

    Thanks

    I hope to do a 3 emiter variant soon ...

    Will
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  27. #27

    Default Re: DIY for Barbolight Bomb-Proof Host with MC-E and McR45 ...

    Wow incredible job. I really appreciated how you took pics and wrote clear descriptions. Even someone like me, not a machinist, could follow it!
    Peace!
    Sygyzy
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  28. #28
    *Flashaholic* wquiles's Avatar
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    Default Re: DIY for Barbolight Bomb-Proof Host with MC-E and McR45 ...

    You are welcome

    Will
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  29. #29
    *Flashaholic* wquiles's Avatar
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    Default Re: DIY for Barbolight Bomb-Proof Host with MC-E and McR45 ...

    Quote Originally Posted by Barbarin View Post
    An impressive job, doing it and documenting it.

    I'm sure Will is going to have some hosts to play with very soon. We are working on a new reflector for P7's and MC-E's (yes, fits both), a little bit deeper than the previous which will increase lux reading at spot by 50% at least if not 100%.

    Javier
    Wait until you see the special 3x MC-E super build that I am currently in the process of building for you as a special purpose dive light ... it will be the bomb

    Will
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  30. #30
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    Default Re: DIY for Barbolight Bomb-Proof Host with MC-E and McR45 ...

    Nice build - and thanks for the story and pics.

    Harry
    Homebuilts - "BREEZE" RCR2 sidexside, "Tornado" 4 x 18650 side x side, Streamlight SL20x LED module (Custom BST Feeler Thread)

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