The 30" Night Hawk

[LightSward]

I jumped ahead and am about half way finished building the 30 Inch "NightHawk".

The 30" reflector mold is one of the best optically, I've ever made; and I did it in two days. Tthe fiberglassing should take one more day. I expect it to make the best beam.

I did this before I did any work on the SportLight or Mini LightSward, because key components ended up in Vegas when the Kia broke down. I hope to get everything back home when the car is fixed and I fly back to Vegas.

I'll post some photos I've taken this week, during next couple days.

[IlluminatedOne]

Cant wait to see what it will be like, always enjoyed seeing the build of the other lights.

[LightSward]

I made this one really fast. It is very light weight, small enough to fit on the car seat, optically about the same as the Gorilla. This is kind of like the next phase of this long multi light study...


30 inch NightHawk design.

Here is the styrofoam and screed plan

Here is the styrofoam and screed plan, used to make the 30 inch Night Hawk reflector.



This is the basic 30 inch Night Hawk Searchlight design using standard geometric procedures.


I wil use the 1200 watt HMI type Jenbo Ballast and ignitor.

Jenbo 1200 watt HMI small arc Metal Halide ballast, is about the size and weight of a motel room Bible...fits in the palm of my hand. Not too expensive either.

Currently I am using several 1200 watt HMI bulbs (one double ended, the other single ended), IgNITEor sold me. Great bulbs, he has great memories with them, I hope to continue that legacy. I will one day replace them with a Jenbo...maybe....another Phillips..???





Jenbo NSK1200 Bulb-Direct Replacement Bulb for Philips MSD 1200 Manufacturer: $128.25


I can't stop working on the Night Hawk...it is addicting. I should have the main light unit finished by tomorrow. Less than a week from start to finish!

[LightSward]

Here is a quick run down on what I have done the last five days or so. Hopefully Thursday Night, (tomorrow), the 30" Night Hawk will come alive.


Foam stack covered with silicone cement using the parabolic screed

Foam sandwich stack covered with silicone cement using the parabolic screed to form final shape and insure precision geometry. this is the same technique mentioned in the "50 inch Monster" thread.



Dry wall compound is drying

Dry wall compound is drying, using a 20 inch fan



Applying one of several coats of paint


Applying one of several coats of paint, red left over from the Gorilla.




Steel frame fitted before glassing

Here I am fitting the steel frame, which consist of electrical conduit, re-bar, metal strapping and framing brackets for the yoke connection. I will add another sealant.


I used a steel frame and much less fiberglass, for reduced weight and cost(s).

[Norm]

Moved to Spotlights and HID Flashlights - Norm

[LightSward]

I am at the next critical phase, the fiber glassing itself.


Wax and lubricant added to mold before glassing


Wax and lubricant added to mold before glassing, to allow a smoother 'release'.




Here I am incasing the steel frame

Here I am incasing the steel frame, which consist of electrical conduit, re-bar, metal strapping and framing brackets for the yoke connection!



Final coat of glass

Final coat of glass is curing.




Finished fiber glassing, cured and removed from mold

Finished fiber glassing, cured and removed from mold, actually mold removed from product...reflector. Not too much destruction to the mold, will be able to re-use much of it.





Completed and back painted

Completed and back painted, the "Night Hawk" is ready for chrome taping...$30.00 worth.


This has been a great project. Now onto the next phase.

[LightSward]

I hope some day to move away from the Chrome Tape, but it is inexpensive, fast and easy to use, with reasonable performance. I am looking at other options, but still don't really have the $$$ to make the change to 'Mirroring' yet...though on the upcoming "Light Sport" I may be in a better position to.


Starting the chrome taping

Here you can see I am starting the chrome taping process, checking the progress with a reflection of my hand.


Finished 30" Night Hawk Reflector


I have finished the 30" Night Hawk Reflector. The reflector came out well, still room for improvement...mostly need to get rid of small burrs, small ridges and other bumps.






Light Weight and easy to handle



The NightHawk is Light Weight and easy to handle. I am using everything I have learned from the prior built lights, to make the "Night Hawk".



1200 Watt HMI Phillips Light Bulb


1200 Watt HMI Phillips Light Bulb bulb is many years old, but still lights up nice and bright!


Building the Bulb housing.


Here I am building the 1200 watt HMI Bulb housing. There is a lot of work in this area, to make the focusing plate and support structures operate properly!


I need to finish the bulb housing and socket support structure, add the reverse back reflector and wire all the components, plus yoke and stand....next few days I should have some good beam shots!

[2100]

Nice....I have followed through your other thread about the 36" Gorilla. Can I ask if you have any experience with PAR56 or PAR64 MH spotlights? I don't think I am up to task in doing up a reflector for myself. There are no commercial spotlights (advertisement ones) in that size as well, all are very big.

[LightSward]

Nice....I have followed through your other thread about the 36" Gorilla. Can I ask if you have any experience with PAR56 or PAR64 MH spotlights? I don't think I am up to task in doing up a reflector for myself. There are no commercial spotlights (advertisement ones) in that size as well, all are very big.

I have limited experience with PARs in general. The ones I have been around are Halogen stage lights that produced incredible beams.

My first large parabolic reflector, over twenty years ago, was made using moist desert dirt as the mold, shaped into a parabolic mound, covered with plastic and then paper mache' and covered with aluminum foil for reflective surface. Actually worked okay.

What are you trying to do?

[2100]

I have limited experience with PARs in general. The ones I have been around are Halogen stage lights that produced incredible beams.
What are you trying to do?

Just trying to build a PAR searchlight with those plastic searchlight as hosts. But i'd like to do metal halide. Metal halide bulbs of 7mm gap and 1200W are attainable, 575W have 5.5mm which are incredible. Inverter/ballast not an issue. But reflector, a good one, is the problem.

[LightSward]

Just trying to build a PAR searchlight with those plastic searchlight as hosts. But i'd like to do metal halide. Metal halide bulbs of 7mm gap and 1200W are attainable, 575W have 5.5mm which are incredible. Inverter/ballast not an issue. But reflector, a good one, is the problem.

Have you checked out the various reflector suppliers like Edmond Scientific? I am at the point myself where making the reflectors needs emphasis on the finishing part, the smoothness and mirroring of the finished product.

[LightSward]

It works!

I've got some incredible beam shots. I'll post them next few days. The Night Hawk, acts like the Gorilla.

I need to do a little focusing, and a little more air circulation to keep the small back reflector from turning yellow, (tarnishing).

[IlluminatedOne]

Cant wait to see the beamshots .

[IgNITEor]

LightSward! You are blazing trails again, brother!
The Night Hawk has come out very nice. You're gettin' super-good at the mold n' finish procedure.
I'm getting all three lights ready for perimeter patrol, and one is a 19" stand-by unit with an almost lousy silvered glass reflector.
No one, and I mean no body, is producing affordable reflectors with usable coatings.
Optiforms and Phoenix Electroformed have focal lengths more suited for Xenon use. Very nice, but spendy for our sizes!
Edmund Scientific's reflectors have great shape but a lousy finish for our lamp uses. I even tried to buff one out with no real success.

Ventilation is crucial, you want to keep the 1200W happy. Sorry to read that the heat is tarnishing your chrome! Bummer!!

Waiting......patiently.....for a beamshot. Don't hurry too much, details are important, right?

[IgNITEor]

Just trying to build a PAR searchlight with those plastic searchlight as hosts. But i'd like to do metal halide. Metal halide bulbs of 7mm gap and 1200W are attainable, 575W have 5.5mm which are incredible. Inverter/ballast not an issue. But reflector, a good one, is the problem.

2100, are these HMI Sharx lamps you're describing or HTI's? I was looking at the HTI type's and they have some serious ventilation requirements
and limited burning positions. Can you post a link to a site describing the 1200 Watt 7 mm gap? I think I saw that lamp in Osram's line-up.
Thanks!

[LightSward]

2100, are these HMI Sharx lamps you're describing or HTI's? I was looking at the HTI type's and they have some serious ventilation requirements
and limited burning positions. Can you post a link to a site describing the 1200 Watt 7 mm gap? I think I saw that lamp in Osram's line-up.
Thanks!

Here is a quick link for 7mm 1200 watt HTI/ HMI: Shark

http://docs.google.com/viewer?a=v&q=...4arpGsQXnBPT7A

The HTI 1200W/D7/60 SharXS lamp is a direct and equal replacement for the HMI 1200W/S lamp.

With a 7 mm electrode gap and 6000 K color temperature, the HTI 1200W/D7/60 SharXS lamp is being used in
fixtures such as Martin Professional and Vari-lite for entertainment applications.

Though the name has changed, technically the lamp is identical: dimensions, electrical properties and
photometrical data…all remain unchanged. The HTI 1200W/D7/75 SharXS lamp is also available in 7500 K color
temperature.
Hope this helps

[LightSward]

LightSward! You are blazing trails again, brother!
The Night Hawk has come out very nice. You're gettin' super-good at the mold n' finish procedure.
I'm getting all three lights ready for perimeter patrol, and one is a 19" stand-by unit with an almost lousy silvered glass reflector.
No one, and I mean no body, is producing affordable reflectors with usable coatings.
Optiforms and Phoenix Electroformed have focal lengths more suited for Xenon use. Very nice, but spendy for our sizes!
Edmund Scientific's reflectors have great shape but a lousy finish for our lamp uses. I even tried to buff one out with no real success.

Ventilation is crucial, you want to keep the 1200W happy. Sorry to read that the heat is tarnishing your chrome! Bummer!!

Waiting......patiently.....for a beamshot. Don't hurry too much, details are important, right?

Thanks, I made this light quick, (one week or so, design/built), to temporarily replace the Gorilla, which is stranded in Las Vegas. Car over heated 20 miles out... I took the single ended Phillips bulb you sold me, socket and Jenbo ballast through security,...raising eye brows and took twenty minutes of x-ray-ing, talking, explaining, (possibly a TSA official may now join CPF), etc...home with me and left the 36 inch reflector in a storage shed. Hopefully KIA won't take this whole month to repair the car...and I can get the Gorilla home safe and sound...roar! I do need to work on the "quality of the surface". The Chrome tape, (has to be exactly the right type, many brands are dull or other issues), works well, but I would like to go for precision and some affordable type of mirroring.

Patrolling sounds kind of fun. I can't say enough...

I think I improved the ventilation, I had a small opening to prevent rain intrusion. the Ladle, Reflector over the bulb is too small, I think it will always tarnish. I really need to find a 5" bowl reflector. These type of bowls I used for back reflectors for several years could be found at: Targets, Wal-Marts, Ross Home Section, many super markets, Kitchen supplies, but now the new 'style', is a flat bottom and straight slanted sides, or dull finish...not good for back reflector use. I have to widen my search.

I did notice the lousy finish on Edmund's reflectors too.

Some Beam Shots coming up soon...couple hours, I may try and do some right now from a couple miles away...??

[LightSward]

So much for the SIMRAN 120 / 220 volt transformer. I got two beam shot photos before this thing blew...fuse just fine...wah....
SIMRAN UPDATE: I found the defective cold-soldered connection on the fuse holder, and fixed the transformer myself. The supplier was trying to blame me for overloading the transformer. I think he is e-mailing off a script.

(CPF is not working too well either lately, I have to log in several times now, just to post a couple photos!)

Here is a beam shot similar to the one of the Gorilla last month.

Night Hawk lights up

This is a composite shot looking almost straight up.




Night hawk by the front door

You can see the temporary shelf board as the Night Hawk stand. The front door provides about the only straight up vantage point for the Night Hawk to beam 'Luxor' style.




Night Hawk beam from back yard

Night Hawk beam from back yard. Living room window in picture.






Night Hawk beam lights the sky

The Night Hawk gracefully lights the night sky.






Night Hawk competes with street light

Even with a bright street light overhead, you can clearly see the Night Hawk beam pointed away from a block away.


I'll post more shots, as I get another 220 volt source, or fix the 120 /220 transformer!
Update: I fixed the transformer while eating lunch! Easy loose wire fix.

[petersmith6]

there little green men on mars putting on the raybands now

[LightSward]

there little green men on mars putting on the raybands now

Even though this is an HMI metal halide lamp, standing a hundred feet away in the light beam is very warm and of course Sunglasses, beach chair, Carona....lol

[LightSward]

Another couple beam shots. I'll get the spot light running again, (hopefully just a loose wire inside the 120 / 220 volt converter; and get some more distant beam shots.



Beam shot from front door

Here is the beam shot from another angle.





Night hawk beam from a block away

Beaming the clouds






Beam shot of the Night Hawk

Beam is somewhat near horizontal, and still lights the clouds up.






The reflector is a little translucent...
Even with three coatings of paint, reflective material, almost as reflective as mirror, and the fiberglass itself, the 1200 watt HMI bulb is very intense, and shines through! I need to work on the focus a little.

I may try the double ended bulb.

[2100]

2100, are these HMI Sharx lamps you're describing or HTI's? I was looking at the HTI type's and they have some serious ventilation requirements
and limited burning positions. Can you post a link to a site describing the 1200 Watt 7 mm gap? I think I saw that lamp in Osram's line-up.
Thanks!

Bro, those are HMIs. http://www.aliexpress.com/product-gs...olesalers.html
I am sure you can a single unit for sale either there or alibaba. I have located a 400W searchlight, probably one of those PAR64 CP60 VNSP cans, ballast and fixture, runs off AC so shouldn't be really expensive....but they just would not reply my emails.

[Triode888@hotmail.com]

Wow, your lights are beautiful.. Congrats..

[LightSward]

Wow, your lights are beautiful.. Congrats..

Thanks. Lots of fun to make these Lights.

Great learning experience; much easier to make, and now obtaining a better product. I am going to concentrate on optical purity now:....making a smoother surface. The parabolic shape is getting quite accurate now, but the slight ripples, blemishes, etc., on the fiberglass surface, need to be smoothed out to the 'immmpth degree of precision...that goal is going to be my next step in making these "monster reflectors", a high quality, affordable item...

I'm also working on other hardware; such as housings, yokes, etc., and will put out a product with maybe a choice of Lamp installations; brand names: such as Jenbo, versus GE, Phillips, etc., or clients can choose to install their own with detailed mounting requirements.

[Bill, Idaho]

Is this a bulb/ballast combination I can fit into my VSS-3 reflector/housing?

[LightSward]

Is this a bulb/ballast combination I can fit into my VSS-3 reflector/housing?

I'm not familiar with the exact dimensions, but what I do know is the 1200 watt HMI is fairly small and the Jenbo ballast is small, about the size of a motel room Bible. The 1200 watt HMI puts out the Lumens of a 2400 watt Xenon...but the Xenon has a much smaller arc, which means you can use a small reflector and get great performance, plus you can turn the Xenon on and off a little quicker than an HMI.

If you switch to HMI or HTI, metal halide, the double ended bulb may be good, because the arc chamber is directly cooled by fan, which allows fairly quick cool down, so that you can turn on and off the lamp in relatively short time. If you use HMI you will have a brighter beam though it widens a little faster.

It is worth looking into, if cost of the Xenon replacement are high or hard to get. HMI are fairly inexpensive.

[LightSward]

I figured out why the 120 to 240 volt transformer quit. Two things, one there was a cold solder joint on the fuse holder that failed when it warmed, two, the the fuse holder was poorly constructed and could barely support the fuse. This is why I was getting 'flickering' with the light. I thought it was the Jenbo ballast from China...if you know what I mean... I fixed both problems with some solder. I am in conversation with the manufacturer about this, as other customers had the same issue, and just threw the transformers out...too expensive to ship for refund.

I got a couple pictures of the Night Hawk, competing with sunlight, and one beam shot just seconds before the solder joint failed the other night.


Close up of the failed solder joint


Carefully opened, unplugged transformer...I've wound, wired and built transformers, so I pretty much knew what was wrong...

carefully opened, unplugged transformer

I figured out why the 120 to 240 volt transformer quit. Two things, one there was a cold solder joint on the fuse holder that failed when it warmed, two, the the fuse holder was poorly constructed and could barely support the fuse. This is why I was getting 'flickering' with the light. I thought it was the Jenbo ballast from China...if you know what I mean...


Night Hawk, on second floor deck.

Night Hawk, on second floor deck, so that I could drive away for a few minutes. I put cardboard near Night Hawk, to keep wash light from shining on neighbor's home.




Beam, as seen half a block away, shining over homes

Beam, as seen half a block away, shining over homes, onto cloud, over a mile up.




As seen from a quarter mile, Night Hawk lights the clouds, over a mile above ground level!
You could see the beam, but the light polluted clouds, made it tough to photograph.




Here is a moving beam shot from five blocks away

Here is a moving beam shot from five blocks away, beam shining directly overhead. the transformer cold soldered joint, failed at about this point. Not too good of a beam shot yet.

[LightSward]

Night Hawk close-up

Night Hawk close-up, with HMI bulb partly in view.




Night Hawk shining for daylight tests

Night Hawk shining for daylight tests on garage doors and sidewalk next to sunshine.




Turned around to see the Night Hawk shining on ME!

Turned around to see the Night Hawk shining on ME! this is what I saw when I turned around. Very warm in beam, don't want to look directly into searchlight...even in broad day light!


With the Night Hawk a hundred feet from this door and me about fifteen feet, makes a nice shadow.

My shadow on garage door 100 feet away from Night Hawk searchlight!

My shadow on garage door 100 feet away from light! Beam seems to spread about thirty inches every hundred feet. I am about fifteen feet in front of garage.






The night Hawk is shining on the garage door

The night Hawk is shining on the garage door, next to car, before it is shined on driveway to compare sunshine brightness.






Night Hawk beam shining with sunlight

Here you can see the Night Hawk shining on the ground next to direct sunlight.

[2100]

Bro, you lux metered the beam at say 100m? It'd be good to know.

[LightSward]

Bro, you lux metered the beam at say 100m? It'd be good to know.

At 100 meters, (I don't have a Lux Meter), but figuring the mature life output of the 1200 watt HMI bulb, inefficiencies of the reflector, and geometry of the light paths and the associated losses and just eyeing it to the 'Lux Chart' on line, I'd say it is around 4,500 to 7,500 Lux on a beam that has spread to around 10 feet in diameter for the bright spot and 12 feet with corona. This is just an educated guess.