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Thread: Aluminium canister + Maglite mod with tree SST50 @5A

  1. #1

    Default Aluminium canister + Maglite mod with tree SST50 @5A

    Hi,
    This is my first post on CPF as writer after a long time as reader only.
    I want to share about my last divelight project.

    The aluminium canister :
    - size of the tube and closure : lenght about 330mm, diameter 60mm
    - batteries: 8 x 18650 ultrafire 2600mAh with a delrin holder cabled as 4S2P
    - possibility to charge individually each battery with a special home-made charger. It was made of 6 ultrafire WF139 in a single box, so it is able to charge 12 x 18650 individually. This is to cycle or equilibrate the cells at home. It need to use the "molex" connector. In use each "molex" connector is configured to create the 4s sub pack.
    - possibility to charge the complete pack during dive travel with a 14.8V charger (or each 4s sub pack)
    - taskled h6flex driver glued on the tube
    - reed contact (no hole in closure) to connect the pack on driver
    - the intensity is drive from the maglite by another reed contact
    - 2 oring on "fixed" closure, 3 oring on screwed closure
    -

    The maglite mod:
    - 3 STT50 5700k @5A so 4500 to 5000 lm expected
    - reed contact to drive the driver placed in canister by a 3 contacts plug.

    The picture of the canister, the maglite mod, the individual cell charger :






    Already tested at 20m deep without electronics and cell : all was OK.
    Ptit Fred
    Last edited by ptit fred; 06-08-2012 at 03:19 PM.

  2. #2
    Administrator Norm's Avatar
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    Default Re: Aluminium canister + Maglite mod with tree SST50 @5A



    Fantastic first post, could you please resize your images to conform with Rule #3 If you post an image in your post, please downsize the image to no larger than 800 x 800 pixels. - Thanks Norm

  3. #3

    Default Re: Aluminium canister + Maglite mod with tree SST50 @5A

    Hi Norm,
    Ok for the size of pictures for my next posts. Sorry.
    Thanks for the approval.
    Ptit Fred

  4. #4
    Administrator Norm's Avatar
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    Default Re: Aluminium canister + Maglite mod with tree SST50 @5A

    You will need to resize the pictures in this post please Fred.

    Norm

  5. #5

    Default Re: Aluminium canister + Maglite mod with tree SST50 @5A

    Ok, pictures have been resized in 800x600.

    Ptit Fred

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    Administrator Norm's Avatar
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    Default Re: Aluminium canister + Maglite mod with tree SST50 @5A

    Quote Originally Posted by ptit fred View Post
    Ok, pictures have been resized in 800x600.

    Ptit Fred
    Perfect thanks Fred.

    Norm

  7. #7
    Flashaholic* Walterk's Avatar
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    Default Re: Aluminium canister + Maglite mod with tree SST50 @5A

    Nice contact boards!
    How about contact heatsink to maglite body? Looks like a lot of play?

  8. #8
    *Flashaholic* wquiles's Avatar
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    Default Re: Aluminium canister + Maglite mod with tree SST50 @5A

    Quote Originally Posted by Walterk View Post
    Nice contact boards!
    +1

    Nice work indeed!
    Please no PM/Visitor Msg's. Email for questions/Paypal: wquiles [at] gmail {dot} com. Please visit my new website.

  9. #9
    Flashaholic* Klem's Avatar
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    Default Re: Aluminium canister + Maglite mod with tree SST50 @5A

    That looks 'bomb-proof'. Excellent work Fred and thanks for sharing.

    I like your idea for allowing the Maglite end to screw up but not twist any wires inside. Just wondering why you didn't leave the nylon cable gland till last to do up, which allows you to untwist the wires as the cap is being screwed on?

    What are you using to focus the beam? What sort of beam are you getting?

    Nice machining by the way.

  10. #10

    Default Re: Aluminium canister + Maglite mod with tree SST50 @5A

    Quote Originally Posted by Walterk View Post
    Nice contact boards!
    How about contact heatsink to maglite body? Looks like a lot of play?
    Hi Walterk,
    Excuse my poor english... and my poor understanding ...
    By "looks like a lot of play", do you want to say a big gap between heatsink and maglite body ?
    In fact the gap is very thin (about 0.05 to 0.1mm).
    The temperature of the 3 leds is transmitted to the maglite body with the help of "arctic" thermal paste.
    On the top of the heatsink (on the side of the glass), i made a place to put an o-ring between (at the junction of) the maglite and the heatsink. This o-ring is used to have a good support for the glass to avoid its failure.

    Ptit Fred

  11. #11

    Default Re: Aluminium canister + Maglite mod with tree SST50 @5A

    Thanks !!!

  12. #12
    Flashaholic* The_Driver's Avatar
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    Default Re: Aluminium canister + Maglite mod with tree SST50 @5A

    Thats a very nice looking light

    O would never use cheap batteries like that in critical application like diving. I also think that they just don't fit in with a high quality light like yours. I would only use protected japanese or korean cells, if I were you (Sanyo, Samsung, Panaosnic, LG, Sony etc.)

  13. #13

    Default Re: Aluminium canister + Maglite mod with tree SST50 @5A

    Quote Originally Posted by Klem View Post
    I like your idea for allowing the Maglite end to screw up but not twist any wires inside. Just wondering why you didn't leave the nylon cable gland till last to do up, which allows you to untwist the wires as the cap is being screwed on?
    I think during repetitive "mounting and unmounting" the external protection of the cable would be deformed and could be problem with waterproof. With this "complicated" solution, i could open/close the maglite as i want without any problem.

    Quote Originally Posted by Klem View Post
    What are you using to focus the beam? What sort of beam are you getting?
    I use 3 Lily reflector from Ledil with an angle of 20-24 degree : http://www.led-tech.de/de/High-Power...92_106_61.html
    I could make some pictures of the beam this evening (the night is not installed yet there) or this weekend.

    Ptit Fred

  14. #14

    Default Re: Aluminium canister + Maglite mod with tree SST50 @5A

    Following some draws of the canister and the maglite body.
    The view of the maglite "top ring screw" is "as delivered" before to be shorten of 2mm to let the place to the 5mm glass.
    In final version, the heatsink and the shorten top ring screw are at the same lenght :








    Ptit Fred
    Last edited by ptit fred; 06-07-2012 at 04:12 PM.

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    Default Re: Aluminium canister + Maglite mod with tree SST50 @5A

    Cool work Fred

    Why do you have three wires to the head? (extra connection thru ball plunger)
    Last edited by arek98; 06-08-2012 at 10:22 AM.

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    Flashaholic* Walterk's Avatar
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    Default Re: Aluminium canister + Maglite mod with tree SST50 @5A

    Quote Originally Posted by ptit fred View Post
    By "looks like a lot of play", do you want to say a big gap between heatsink and maglite body ?
    In fact the gap is very thin (about 0.05 to 0.1mm).
    I understand now, the cooling is to the tube not to the reflectorhead.

    Nice to see how you made sketches beforehand. What software did you use?

  17. #17

    Default Re: Aluminium canister + Maglite mod with tree SST50 @5A

    Quote Originally Posted by arek98 View Post
    Cool work Fred

    Why do you have three wires to the head? (extra connection thru ball plunger)
    Hi Arek98,
    The third wire is used to drive the driver power from the maglite.
    I have a reed contact in the maglite head to drive the power of the Taskled H6flex driver (see on www.taskled.com).
    When the reed is on, this wire is connected the + power supply (14.8V in my project) of the maglite head. Then, the tension return to the canister to drive a very little relay (5V coil 1A contact via a tension divider = potentiometer). It rise the tension of the coil to 5V to create a contact.
    The pins of this contact are connected to the 2 switch pins of the driver (SWA and SWB of the H6Flex driver). This allow to change the power of the 3 SST50.

    Ptit Fred

  18. #18

    Default Re: Aluminium canister + Maglite mod with tree SST50 @5A

    Hi Walterk,

    Quote Originally Posted by Walterk View Post
    I understand now, the cooling is to the tube not to the reflectorhead.
    In fact, the cooling is made by the head and the tube. The heatsink has a tolerance of 0.1mm with the tube and the head of the maglite.


    Quote Originally Posted by Walterk View Post
    What software did you use?
    I use Solidworks software.

    Ptit Fred

  19. #19
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    Default Re: Aluminium canister + Maglite mod with tree SST50 @5A

    Ok, I missed a part about switch being in the head.
    Neat solution for having switch in head and still short run to flex driver switch (SWA and SWB pads, which is recommended by George). Cool.

  20. #20
    Flashaholic* lucca brassi's Avatar
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    Default Re: Aluminium canister + Maglite mod with tree SST50 @5A

    Nice work , how much head and canister weight ?

    P.S. You could avoid ball plunger and power connector by twisting cables with turns in opposite direction ( in that case you need space in back )

  21. #21

    Default Re: Aluminium canister + Maglite mod with tree SST50 @5A

    Quote Originally Posted by lucca brassi View Post
    Nice work , how much head and canister weight ?
    The weight of the complete light "ready to dive" as shown on the first picture of this discussion (canister with its "STA" and belt, battery, head with its "goodman" grip) is 2,680kg

    Quote Originally Posted by lucca brassi View Post
    You could avoid ball plunger and power connector by twisting cables with turns in opposite direction ( in that case you need space in back )
    I had tried the twist on an old project based on a maglite modded to halogen dichroic + canister. After 2-3 mounting/unmounting the wire had failed.
    As you explain : I hadn't let enought space back to twist safely the wire. But there, i had no solution to increase the space back. So i made this 3 turning contacts.

    For this last project, i keep the same solution which, i agree, is more complicated than twist.

    Ptit Fred

  22. #22

    Default Re: Aluminium canister + Maglite mod with tree SST50 @5A

    i love your heatsink desinged, any infos where you get that?

  23. #23

    Default Re: Aluminium canister + Maglite mod with tree SST50 @5A

    Quote Originally Posted by wannabe333 View Post
    i love your heatsink desinged, any infos where you get that?
    It is self-made. I have the chance to access to a lathe in my job.

    Ptit Fred

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