Single XM-L to TRIPLE XM-L - build log of 3000-lumen light...

Chicago X · Jan 16, 2012

I really like this torch. There's nothing wrong with it in stock form, but what couldn't be made better by upping the power four- to fivefold ?

The plan is to yank out the guts, replace with billet aluminum, then cram in a TRIPLE XM-L U2 setup with a 4-5A Turbo DRY driver. Can you say 3000 lumen out-the front ? Hehe...
Here's a seller pic as a reminder:

Link to TORCH here: http://www.cnqualitygoods.com/goods.php?id=1207
Link to HOST here: http://www.cnqualitygoods.com/goods.php?id=1208
http://www.cnqualitygoods.com/goods.php?id=1208Link to REVIEW here:

Here's a shot of the stock emitter, stock reflector.

Since I wanted the mass of the "pill" to be as much as possible, I worked from the bezel, rearward.
I cut a ring out of 6061 Aluminum, then cut a beveled edge to hold the optic:

Here's the optic and triple XM-L board from www.Cutter.au :

Optic in new retainer ring:

Here's what it looks like, test-fit in the bezel :

With LED board:

Coming up, the pill.

Chicago X · Jan 16, 2012

Here's the DRY Turbo driver, from Ric at CNQG:

Here's the battery side (bottom) of the billet heatsink, also from 6061 Aluminum:

Top:

Side (with chuck marks):

Here's the driver, seated in the heatsink:

Here's the light engine:

Here's the heatsink fit in the head of the torch:

Buttoned-up in the rear for a good fit:

New vs. old:

Next, comes the battery-holder mods and soldering.
Stay tuned !!!

Chicago X · Jan 16, 2012

Here are the details of the battery holder mods.
Overview: Converting a 3x18650 battery holder from parallel to series operation.
Here are a few pics of the stock battery holder:

As you can see, the holder needs to bring both + and - to the top end, as the body does not have a ground path...it's entirely anodized.
The first modification was to cut the trace on the PCB, linking two spots on each one. I failed to notice these initially, and this led to a short (and melted springs.)
Working from the switch to the top spring, linking + and -, requires a bit of wire:

The extra wires are used to make for a better negative pathway:

Here you can see the addition of 2 contact points to the negative (ground) ends:

Here's a look at the modded holder, reading 12.61 volts:

Next round will be the assembly/wiring of the Light Engine.

Chicago X · Jan 16, 2012

The 3-up board has been soldered to the driver:

A thin film of Arctic Silver adhesive was placed under the board, then the optic placed on the board, then the whole assembly put under light pressure. The AS should hold the optic in place, obviating the need for CA glue.

Next will be affixing the driver to the light engine.

Chicago X · Jan 16, 2012

Since this thing is going to pull 4-5 amps at 12.6v, I wanted to upgrade the wiring I had on-hand. I used some silver plated copper Teflon-coated wire:

Here's the upgrade:

Some heatsink stuff from another light was placed in the driver pocket:

The modified wiring was then soldered:

Since the original pill screwed into the head, I needed a way to provide positive pressure to the bottom of the new light engine. The original pill was used:

I cut a ring from the heatsink, then notched it for wire clearance. I may want to upgrade some day.

Chicago X · Jan 16, 2012

Here's the battery plate soldered on:

Buttoned up, stock and modded:

Before, without cells:

After, no cells:

Testing.......IT'S ALIVE !!!!!

Next come the night-ending beamshots.

Chicago X · Jan 16, 2012

Here's a quick iPhone pic. On the right is the stock 700 lumen single XM-L CQG light at 2.8A, on the left the modded 3 x U2 XM-L at ~4A (turbo) estimated at ~3000 OTF.
Even my wife said "wow" at the new torch.

I will get some outdoor beamshots soon, comparing this to some well-known lights.
__________________

texas cop · Jan 16, 2012

And when do you go into production? Great conversion job.

ICUDoc · Jan 16, 2012

Great job- looks excellent!

beekeeper5 · Jan 16, 2012

Nice job! Is the light more throw or flood?

Chicago X · Jan 16, 2012

Thanks, guys !

With these optics, it's all flood after about 30 feet. This is the proverbial "wall of light" like I've never seen...it simply illuminates EVERYTHING around you, evenly.

Chicago X · Jan 18, 2012

Reliability testing is ongoing, with about 1 hour of nightly use. (Walking dogs)

The light only gets hot on Turbo. It gets just a bit warm on High mode, and the estimated 2400 lumen output is plenty.

This host continues to impress me.

CyberCT · Jan 26, 2012

I'm new to modding and I can understand what you did the first halfway though ... but you lost me on the whole battery carrier and how to mod it. That's beyond my comprehension at this time (I understand the concept but not how to put it in place from parallel to series). Did that tripple LED board come that way or did you reflow them on? I would love to do the same but with neutral XMLs

yifu · Mar 4, 2012

Wow, nice work! The LEDs attached to the heatsink looks very much like a P60 triple drop in! I wonder if someday we will get triple XML P60 drop ins. Heat might be an issue, but not really if you've got a FiveMega Beefy heat sink!

Illum · Mar 4, 2012

Beautiful mod, well done! :clap:

4-5 amps at 12.6v :thinking:
Those Panasonic 18650s might complain if you leave it on too long

Single XM-L to TRIPLE XM-L - build log of 3000-lumen light...

Chicago X

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