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Thread: Kavelight P60 Headlamp

  1. #1
    Flashaholic* kevinm's Avatar
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    Party Kavelight P60 Headlamp

    Hi all,

    After a lot of time being frustrated by caving headlamps I can afford and wanting the ones I can't, I built my own! This headlamp uses P60 and 26mm drop-ins, so it's user upgradeable. Though it was originally designed to be a caving headlamp (and is more than tough enough for that), people who bought one use them for mountain biking, outdoor adventuring, and orienteering. Details below!

    previous thread: http://www.candlepowerforums.com/vb/...th-prototype!)




    Details:
    Made in Colorado!

    body: 1.5-6mm thick machined from T6 6061 aluminum
    hard anodized 2 mils thick in CPF red (twice the minimum military standard thickness)
    according to SolidWorks, capable of holding 1800lbs before deforming

    lens: 1/8" thick Lexan

    switch: waterproof and dust proof to IP68x
    mechanical (won't mess with your compass)
    10A, 30V DC
    made by a US aerospace manufacturing firm and each batch (15 at a time) of components is tested
    very low resistance; no noticeable voltage drop at 4 amps

    cable glands: waterproof to IP68, 5 bars

    cable: fire retardant, chemical, radiation, and abrasion resistant

    connectors: same as Stenlight

    battery case: battery carrier inside holds 4x18650's wired for 3.7V, 7.4V, or 14.8
    waterproof
    machined from the same aluminum

    copper clad circuit board for contacts

    blade mount or aluminum bracket mount

    CPF package $225 net to me (shipped in USA):
    head with your choice of mount (blade mount or helmet bracket)
    battery pack wired to your choice of voltage
    cable length 1-4ft, your choice

    FULL package $350 net to me (shipped in USA):
    head with your choice of mount (blade mount or helmet bracket)
    battery pack wired to your choice of voltage
    cable length 1-4ft, your choice
    4 18650 batteries
    1 charger
    flood module
    2 drop ins (one flood, one spot, programmed to whatever modes you want)

    Additional Options:
    extra cables
    longer cables
    no battery case
    battery pack (like the Stenlight ones)
    less durable but larger gauge cable (for drop-ins above 3.5A)
    extra battery carrier for different voltage (swappable)
    headband
    handlebar mount

    All the additional options cost extra, but how much depends on what you want.

    It's heavier than a Stenlight, but lighter than a Scurion. Exact weight depends on the drop-in and mounting option.


    Compatibility:
    So far, users have run Malkoff, Nailbender, Anto, Solarforce, and VanIsles drop-ins in these. At amperages above 3.5A, I'd suggest the optional cable. I'm looking forward to trying a Moddoo triple in one too! With all of these heat management has not been an issue. If you wrap your drop-ins in copper tape, go easy on it; the tolerances are pretty tight.

    I have all the parts for 4 of these right now. The next batch of switches will be here in a month.

    Oh, and the name's not fixed in stone yet... Kavelight or...

    I'll ship outside the US; it just costs a little more.

    Thanks for looking!
    Kevin
    Last edited by kevinm; 12-06-2012 at 10:25 PM.

  2. #2
    Flashaholic* kevinm's Avatar
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    Default Re: Kavelight P60 Headlamp

    Here's a review (with better pictures than mine!):

    http://www.candlepowerforums.com/vb/...-(mini-review)
    Last edited by kevinm; 02-15-2012 at 11:34 AM.

  3. #3
    Flashaholic* psychbeat's Avatar
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    Default Re: Kavelight P60 Headlamp

    these things are TOUGH!!!

    I had a pretty good crash on my bike last night (cracked my visor) and smashed
    my KAVElight into a clay berm. Im fine thanks to my fullface helmet


    the ano is so thick on these there isnt a scratch!

    Hey Kevin- does the optional pack just use the same molex and is it a
    thinner case that goes around the plastic cell carrier or does it do away with
    the carrier all together?

    might be cool to have for light backpacking trips where I dont need the aluminum
    case etc.

    oh yeah you might want to mention that the switch has almost NO measurable resistance
    well I tested mine to ~4a + and couldnt detect any voltage drop with my DMM

    sign me up for a floody switch module when they happen!

  4. #4
    karlthev's Avatar
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    Default Re: Kavelight P60 Headlamp

    I have two....they are fine pieces of equipment!


    Karl

  5. #5
    Flashaholic* kevinm's Avatar
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    Default Re: Kavelight P60 Headlamp

    Quote Originally Posted by psychbeat View Post
    these things are TOUGH!!!

    I had a pretty good crash on my bike last night (cracked my visor) and smashed
    my KAVElight into a clay berm. Im fine thanks to my fullface helmet


    the ano is so thick on these there isnt a scratch!
    No more face plant testing! Seriously, I'm glad you're okay.

    Quote Originally Posted by psychbeat View Post
    Hey Kevin- does the optional pack just use the same molex and is it a
    thinner case that goes around the plastic cell carrier or does it do away with
    the carrier all together?

    might be cool to have for light backpacking trips where I dont need the aluminum
    case etc.
    No carrier at all; just a couple of batteries tabbed together and dipped in PlastiDip a bunch of times. It's the same Molex .062" connector.

    Quote Originally Posted by psychbeat View Post
    oh yeah you might want to mention that the switch has almost NO measurable resistance
    well I tested mine to ~4a + and couldnt detect any voltage drop with my DMM
    Edited the original post; thanks!

    Quote Originally Posted by psychbeat View Post
    sign me up for a floody switch module when they happen!
    You're first on the list! Oops...I mean second.
    Last edited by kevinm; 02-15-2012 at 11:30 AM.

  6. #6
    Flashaholic* kevinm's Avatar
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    Default Re: Kavelight P60 Headlamp

    Quote Originally Posted by karlthev View Post
    I have two....they are fine pieces of equipment!


    Karl
    Thanks, Karl!

  7. #7
    karlthev's Avatar
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    Default Re: Kavelight P60 Headlamp

    Well then Kevin, numbers two and three on the floody switch module--one for each of mine!!!



    Karl

  8. #8
    Flashaholic* LEDAdd1ct's Avatar
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    Default Re: Kavelight P60 Headlamp

    Very handsome light—excellent work and good luck with sales!
    "...and the diode multiplied and grew in brightness. And God saw that it was good."

  9. #9

    Default Re: Kavelight P60 Headlamp

    Hey, *I* was first on that list!

    http://www.candlepowerforums.com/vb/...=1#post3824465

    Put a Nailbender 4.2 A XML in there and it's suddenly daytime. Not too hard to switch modes, either. I haven't done any stunt testing but I definitely love mine. How much for 3' of the heavy duty cable?
    Last edited by RCantor; 02-11-2012 at 03:32 PM. Reason: Proof!!! :)

  10. #10
    Flashaholic* kevinm's Avatar
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    Default Re: Kavelight P60 Headlamp

    Quote Originally Posted by RCantor View Post
    Hey, *I* was first on that list!

    http://www.candlepowerforums.com/vb/showthread.php?323904-Feeler-Custom-P60-Headlamp-(with-prototype!)&p=3824465&viewfull=1#post3824465

    Put a Nailbender 4.2 A XML in there and it's suddenly daytime. Not too hard to switch modes, either. I haven't done any stunt testing but I definitely love mine. How much for 3' of the heavy duty cable?
    Right you are, sir!!!

    1. RCantor
    2. Psychbeat
    3. Karlthev
    4. Karlthev

    I think the heavy draw cable will be $4 a foot + connectors, but I have to see what McmasterCarr charges me for shipping. Whatever it is, it'll be at cost.

  11. #11
    Flashaholic* kevinm's Avatar
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    Default Re: Kavelight P60 Headlamp

    Quote Originally Posted by LEDAdd1ct View Post
    Very handsome light—excellent work and good luck with sales!
    Thanks!

  12. #12
    Flashaholic* kevinm's Avatar
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    Default Re: Kavelight P60 Headlamp

    I designed the module for the other side of the headlamp this weekend. The prototype should be here Feb 23rd; then, I can get quotes on the cost of production!

  13. #13
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    Default Re: Kavelight P60 Headlamp

    YaHOOOOOOOOO!!!!!!!!!! Keep us all posted Kevin!!!



    Karl

  14. #14
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    Default Re: Kavelight P60 Headlamp

    I just wanted to give some info here regarding a TorchLAB L3 from Oveready which I tried to install in my Kavelight P60 Headlamps---no go! This is a great P60 module but just a tad too large in diameter for the Kavelight.



    Karl

  15. #15
    Flashaholic* kevinm's Avatar
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    Default Re: Kavelight P60 Headlamp

    Awwwwww, man! Which dimension is too large, Karl? Can you post a picture?

    Kevin

  16. #16
    karlthev's Avatar
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    Default Re: Kavelight P60 Headlamp

    I really can't seem to take a picture of where the drop in is hanging up...nor even can see exactly. I'd have to hazzard a guess and say only a few thousands...? The diameter in the Kavelight is just a tad too small.

    Karl

  17. #17
    Flashaholic* psychbeat's Avatar
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    Default

    U can probably just sand the module a bit. My VANisleDSM felt ultra snug
    I didn't install it for fear of not being able to get it out!

    I may eventually drill a small hole somewhere so I can remove tight drops.
    Also I could get a tighter press for for heat transmission etc

  18. #18
    Flashaholic* kevinm's Avatar
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    Default Re: Kavelight P60 Headlamp

    I'd try sanding a little too. I think Moddoo and I both went a little overboard on the anno thickness.

    I'm waiting for a reply from Moddoo with specs for the modules to see how far off we are.

  19. #19
    karlthev's Avatar
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    Default Re: Kavelight P60 Headlamp

    Well....I'm afraid of sanding through the anno for fear I may short out the module. At $165 a "pop", I really don't want to hear a "pop" or see any "magic smoke"..... I think I'll wait to see if there will be any problems if I sand through....


    Karl

  20. #20
    karlthev's Avatar
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    Default Re: Kavelight P60 Headlamp

    I didn't want my last post to appear to be negative about this fine headlamp. I love it! It's a great build in my opinion and, I have other hosts which will accept this module so I am not out the money with no place to go. I just wanted to be sure that others might not wish to use this same drop in and find the same as I did. I already have another drop in "installed" in my second Kavelight P60!!!



    Karl

  21. #21
    Flashaholic* kevinm's Avatar
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    Default Re: Kavelight P60 Headlamp

    Quote Originally Posted by karlthev View Post
    Well....I'm afraid of sanding through the anno for fear I may short out the module. At $165 a "pop", I really don't want to hear a "pop" or see any "magic smoke"..... I think I'll wait to see if there will be any problems if I sand through....


    Karl
    Good call Karl; they are expensive (but, from what I read, worth it)! I keep trying to PM Moddoo, but his box is full. Let's get info before sanding.

    Kevin

  22. #22
    Flashaholic* kevinm's Avatar
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    Default Re: Kavelight P60 Headlamp

    Quote Originally Posted by karlthev View Post
    I didn't want my last post to appear to be negative about this fine headlamp. I love it! It's a great build in my opinion and, I have other hosts which will accept this module so I am not out the money with no place to go. I just wanted to be sure that others might not wish to use this same drop in and find the same as I did. I already have another drop in "installed" in my second Kavelight P60!!!

    Karl
    Thanks! I'd rather have people know they don't fit than not. I'm bummed about those drop-ins not fitting; I wanted one myself!

    Hopefully, it's a thousandth too big and we can take .5 thou off each...

  23. #23
    Flashaholic* Moddoo's Avatar
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    Default Re: Kavelight P60 Headlamp

    Hey Guys,

    I was out of town for several days.

    My Triples are built for a guaranteed fit into Surefire hosts.
    The largest the Triple Drop-in heatsinks have ever been made is .8730" finished diameter after hardcoat.
    Having handled a few thousand SF hosts, I can say with confidence that they very rarely measure under .8740"

    What size is the finished diameter of your drop-in pocket on the headlamp?

  24. #24
    Flashaholic* kevinm's Avatar
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    Default Re: Kavelight P60 Headlamp

    Quote Originally Posted by Moddoo View Post
    Hey Guys,

    I was out of town for several days.

    My Triples are built for a guaranteed fit into Surefire hosts.
    The largest the Triple Drop-in heatsinks have ever been made is .8730" finished diameter after hardcoat.
    Having handled a few thousand SF hosts, I can say with confidence that they very rarely measure under .8740"

    What size is the finished diameter of your drop-in pocket on the headlamp?
    Moddoo! Welcome back! The hole in the headlamp is just over 22mm, so .8661" or a little over. I'll measure again tonight and update this post.

    What happens if people sand the sides of the drop-in a little?

    With the host, it shouldn't make any difference in operation, other than it won't be electrically isolating anymore. It would be like the uncoated interior of the P6 then.
    Last edited by kevinm; 02-20-2012 at 05:27 PM. Reason: Measured!

  25. #25
    Flashaholic* Moddoo's Avatar
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    Default Re: Kavelight P60 Headlamp

    Quote Originally Posted by kevinm View Post
    Moddoo! Welcome back! The hole in the headlamp is just over 22mm, so .8661" or a little over. I'll measure again tonight and update this post.

    What happens if people sand the sides of the drop-in a little?
    Hey man, thanks.

    what happens...
    frustration, tired hands, nasty looking drop-in after a lot of effort.

    Hardcoat is not easy to remove, and the difference in diameters is a lot to take off by hand.
    You would need to go well beyond the hardcoat layer

    Boring the Kavelight to the size of a SF host is a better idea IMO.

    Quote Originally Posted by kevinm View Post
    With the host, it shouldn't make any difference in operation, other than it won't be electrically isolating anymore. It would be like the uncoated interior of the P6 then.
    I'm not sure how many parts you have completed, but a revision to the next batch would be a good idea I think.
    Depending on your relationship with the machine shop, you may be able to have the existing parts reworked for a decent price.

  26. #26
    Flashaholic* kevinm's Avatar
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    Default Re: Kavelight P60 Headlamp

    Quote Originally Posted by Moddoo View Post
    Hey man, thanks.

    what happens...
    frustration, tired hands, nasty looking drop-in after a lot of effort.
    Sounds like a good rock-climbing workout!

    Quote Originally Posted by Moddoo View Post
    Hardcoat is not easy to remove, and the difference in diameters is a lot to take off by hand.
    You would need to go well beyond the hardcoat layer

    Boring the Kavelight to the size of a SF host is a better idea IMO.
    Probably true. I have 12 or 13 that have not been annodized that I could probably bore out at the machine shop myself.



    Quote Originally Posted by Moddoo View Post
    I'm not sure how many parts you have completed, but a revision to the next batch would be a good idea I think.
    Depending on your relationship with the machine shop, you may be able to have the existing parts reworked for a decent price.
    I'll ask; thanks for the input.

    Don't sand anything yet guys!

  27. #27
    Flashaholic* kevinm's Avatar
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    Default Re: Kavelight P60 Headlamp

    Okay, all the annodized ones I have measure .8665" or .8670". So we're .006 off; so close! The unannodized ones measure .8685-.8690", making the anno as thick as we thought.

    Let me find out how much work or expense it would be to have them bored out a little. I might also sand one of the raw ones to see how that would work.

  28. #28
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    Default Re: Kavelight P60 Headlamp

    Let me say that I have already purchased a P60 dropin with a Cree with reputed throw that will be going into this fine headlamp awaiting the build of the spill setup for the square section of the light! I'm happy as a clam...outspoken clam....



    Karl

  29. #29
    Flashaholic* kevinm's Avatar
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    Default Re: Kavelight P60 Headlamp

    Nice! You'll have both spot and flood (hopefully) soon!

  30. #30
    Flashaholic* kevinm's Avatar
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    Default Re: Kavelight P60 Headlamp

    I have a plan for VanIsles and Moddoo/Torchlab drop-ins! I have a bunch of unanodized headlamps. I'm going to take one to the machine shop and use a 7/8" drill or 7/8" end mill to make them fit!

    If I can pull this off and it works well, I'll do this to the rest of the headlamps, anodize them, then swap them out (for those of you that want to send yours back for a week or so). Hopefully, I can do this at the same time as the second modules to minimize shipping and the time I'll have your headlamps.

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