Been busy for a little while, here's some updates I made on other forums about a week ago:
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The driver I'm using has an diameter of 33mm and the heatsink ID is 27mm and the OD is 34mm, if I tried to machine it down, I'd be left with a 1mm wall. So I'm going to cut the rear of the heatsink off so I can mount my driver to the heatsink and still be able to use thermal protection. I'll do some more thinking when I have everything in my hands, however I'll be working on voltage monitor led this week which will include a resistor, a small circuit board, and an led in the color of red, orange, blue, or green...which color do you guys think?
Total spent on this project thus far(rounded off of course):
$22 4D maglite
$67 4x 32650 lithium ion batteries
$14 2x UCL glass lens
18€ 3x reflector
17€ Aluminum heatsink
27€ Custom star pcb with three xm-l t6 LEDs
3.45€ International shipping
So far around $200, budget is at $300
I may add glow in the dark o-rings like I have on my xm-l mini maglite, as well as a stainless steel bezel for looks and added durability.
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Been a couple days since my last update, hadn't done much but got my simple battery voltage monitor led put in. Didn't get good pictures and I'm honestly not 100% satisfied with the looks of the messy epoxy glob, but it does hold and it does works. If I can locate another maglite switch, I may make a version 2 mag switch without the messy epoxy and use plastic spacers and screws instead.
I'm also thinking about getting into the business of building custom maglites...err....another thread on that later.
It's been suggested to use clear plastic rods instead of fiber optic cables to transfer light from the voltage monitor led to just above the switch. I'm getting excited now!
I'm out of town now, but two of three packages should have arrived today or will arrive on Monday. I'm wondering if my package from germany has been delayed due to irene. Aside from making version 2 of my switch and drill the hole for my optical plug, I'll be at a standstill without my headsink...
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(6 days ago)
Just contacted my supplier in Germany that he shipped out on the 24th, so I'm expecting my order to be in around sept 2nd to 7th. My lithium ion cells and UCL glass should be arriving any minute now.
Going to Lowe's to look at drill presses, since I figured out my fiber optics problem thanks to a member on here(credit will be given when I find his/her screen name).
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(4 days ago)
Well, the messy white epoxy killed my original maglite switch so version two is in the works with a different wiring layout and the circuit board with the status led and resistor will be screwed on instead of epoxied like the last switch. Also note that this is the newer model maglite switch and not an older model like my original modified maglite switch. Here's some teaser pictures:
Amazing how much better quality switch one can make with a new drill press, perhaps I can upload pictures of that, but currently sitting in a hospital room. Maybe tomorrow....
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(3 days ago)
Some video updates:
d0faa4a8.mp4 video by cdrake261 - Photobucket
1d1d6140.mp4 video by cdrake261 - Photobucket
Also, I forgot to mention my 4 lithium ion batteries went AWOL but hopefully they will show up today, I'm also expecting my german shipment on Friday, so keep a look out for more updates.