LightForce SL240 HID Conversion

Sway · #1 02-12-2004, 04:33 PM

I have been wanting a HID light for sometime but everything was out of my price range so I was stuck on the bench while many other were in the game having fun. While ridding the pine so to say I had time to think and scheme, I already have a LightForce SL240 Blitz one of the longest throwing off the shelf 100W Halogens but the reflector is a metallised polymer so a higher wattage lamp will result in melt down.

LightForce has an off road vehicle HID system but it's a different animal from the hand held lights and very expensive.

I contacted LightForce and confirmed the reflector was the same in the hand held and off road light so I had to figure out how to convert the Blitz to HID. I ordered a KenRad 35/50W boost ballast, igniter and a Osram D2S lamp. If you are familiar with the Blitz the only thing big about it is the reflector so you don’t have a lot of room to work with so the ballast and igniter has to be mounted outside of the light.

It took several hours of trimming and filing to get the socket and lamp base down to size so they would fit inside the handle but I think the results were worth while. I’m still working something’s out as far at the ballast and igniter but the performance should remain the same. All HID pictures were made using the 50W boost have a look.

Halogen Blitz around 215 Yds.

HID Blitz

½ Mile white golf ball thingy.
Halogen Blitz (old pic using a little zoom)

HID Blitz

Later
Sway

Ginseng · #2 02-12-2004, 06:29 PM

That is F$@#*$& insane! I love it! Nice work Sway. So, um, PayPal sent [img]/ubbthreads/images/graemlins/grin.gif[/img]

Wilkey

AilSnail · #3 02-12-2004, 07:28 PM

Wow sway!

That looks like a worthwhile upgrade for sure.

Sway · #4 02-12-2004, 07:36 PM

Thanks Wilkey!!!!

I still have something’s to work out the such as rotating the light engine so the shadow of the return wire will be at the top, it really shows up more in the pic’s than what you actually see. I just need to find the right project box to house the ballast and igniter to be done with it.

Later
Sway

Sway · #5 02-12-2004, 07:56 PM

Ail,

It's a monster compared to what I’m use to, you just have to give it a little time to warm up for full out put and I’m not sure that I did that in the 150 yard shot at the church now that I look back as the color is a little off.

Later
Sway

cheesehead · #6 02-12-2004, 08:12 PM

Hey, excellent work. Also, good point about the return wire, I didn't even notice it at first, but it makes sense to have the bulb flipped the other way. Does that make a difference in how the bulb works or lasts? Seems some sites say it does, but it seems to make more sense that it doesn't.

Looks like a keeper! FANTASTIC!

cheese

Sway · #7 02-12-2004, 08:31 PM

Thanks Cheese!!!

I need to do more research on the orientation of the return wire right now I don’t know [img]/ubbthreads/images/graemlins/icon3.gif[/img]

Shovel stuck in the yard duct tape pic, Humm ShovelPod? [img]/ubbthreads/images/graemlins/wink2.gif[/img]

Later
Sway

AilSnail · #8 02-12-2004, 09:03 PM

Holy ballast. what a beamshot.

[ail succumbs]

jtice · #9 02-12-2004, 09:16 PM

muuuuuuhahahahahahahahahahahahahaha

I feel the power surging through me just looking at that monster!!!!!

EXCELLENT WORK KELLY !!!!

This is truely inspirational.

The ol NELCO is gonna have to meet Mr HID [img]/ubbthreads/images/graemlins/wink.gif[/img]

[img]/ubbthreads/images/graemlins/bowdown.gif[/img][img]/ubbthreads/images/graemlins/bowdown.gif[/img][img]/ubbthreads/images/graemlins/bowdown.gif[/img][img]/ubbthreads/images/graemlins/bowdown.gif[/img][img]/ubbthreads/images/graemlins/bowdown.gif[/img][img]/ubbthreads/images/graemlins/bowdown.gif[/img][img]/ubbthreads/images/graemlins/bowdown.gif[/img][img]/ubbthreads/images/graemlins/bowdown.gif[/img][img]/ubbthreads/images/graemlins/bowdown.gif[/img][img]/ubbthreads/images/graemlins/bowdown.gif[/img]

jetweed · #10 02-12-2004, 09:22 PM

All I can say is;

I'm batman.

Nerd · #11 02-12-2004, 11:06 PM

Looks like this thing can throw for tens of miles... fantastic work dood! Now pop a 100 watt HID into this light! [img]/ubbthreads/images/graemlins/grin.gif[/img]

flash.... · #12 02-13-2004, 10:54 AM

If I may ask... How much $$ and where specifically did you get all of the parts to build this AWESOME beast??? (I want one) [img]/ubbthreads/images/graemlins/grin.gif[/img]

Sway · #13 02-13-2004, 01:46 PM

Flash,

Ballast and igniter Model EB035/50G01 175.00
Osram D2S Light Engine came from ebay $39.00
LightForce dealer page SL240 Blitz $129.00
Total $343.00 not including postage on the items. A X990 is $549.00 around $200.00 differnece depending what kind of deal you get.

These prices are retail work your best deal plus you get the fun of pulling you hair out trying to find the best configuration and thats FREE!

I'm going to try another confuguration soon as I don't like the way it looks but with this light anything is going to look tacked on you just have to live with it. I will post some pic's when it's done.
Later
Sway

AilSnail · #14 02-13-2004, 04:48 PM

can you maintain the seals too?

Sway · #15 02-13-2004, 05:18 PM

Ail,

Well yes and no the light is not water tight from the start, where the power cord comes in at the bottom of the handle is a weak point. The seals where the reflector screws onto the handle are not affected as I have the light apart right now here is a pic of what the lamp looks like installed in the handle.

Hope this helps [img]/ubbthreads/images/graemlins/smile.gif[/img]

Later
Sway

AlexGT · #16 02-13-2004, 10:01 PM

That thing rocks! Congratulations! [img]/ubbthreads/images/graemlins/thumbsup.gif[/img] [img]/ubbthreads/images/graemlins/buttrock.gif[/img]

Will you be making these mods for sale?

Alex

flash.... · #17 02-13-2004, 10:29 PM

Sway...
That rocks... [img]/ubbthreads/images/graemlins/buttrock.gif[/img] I need to pinch a $ here and there, but your information will help me in my quest to now top my 990!! for a price that won't kill me. [img]/ubbthreads/images/graemlins/xyxgun.gif[/img]

Thanks again! [img]/ubbthreads/images/graemlins/thumbsup.gif[/img]

Nerd · #18 02-13-2004, 10:36 PM

Sway Sway... here I come to clear up the pics again! Your lights are always so bright they always throw off the camera's exposure balance.

Yeah, that's a light sabre reaching for the heavens, and Sway placed his light on a shovel stuck in the ground. [img]/ubbthreads/images/graemlins/grin.gif[/img]

*edit* dang.. image station is not working...

*edit* Now it's on ticey's server [img]/ubbthreads/images/graemlins/smile.gif[/img]

paulr · #19 02-13-2004, 10:45 PM

Holy moly...

NightStorm · #20 02-14-2004, 01:14 PM

Sway,

Nasa called and they want you to stop annoying the astronauts on the International Space Station. [img]/ubbthreads/images/graemlins/grin.gif[/img] Me likey!! [img]/ubbthreads/images/graemlins/thumbsup.gif[/img]

Dan

Zelandeth · #21 02-14-2004, 03:56 PM

One word: Impressive!

Hmm...only $250 out of my budget...drat.

[img]/ubbthreads/images/graemlins/broke.gif[/img]

AilSnail · #22 02-14-2004, 04:50 PM

sway, I didn't inspect my ML240 too closely yet. Are you saying that where the power cord enters the light is the weak point in the sealing system? Then would it help to put a dab or two of sikaflex or something there?

It looks like the oring on the tube-shaped part is a bit loose on mine. I will see if I can find a tighter one. It is probably ok though. I don't intend to swim with it but it stays on a fishing vessel...

Incidentally the through-roof remote control doesn't look too shabby after all. I am not sure yet whether it can stay in any vertical position or if it will return to neutral. Need a *big* drill bit (2" or so) to pierce the roof.

It is already a mightily impressive light. Do you like the colour of the auto hid compared to the incan?

Sway · #23 02-14-2004, 05:41 PM

Ail,

I think the light is water resistant being if anything did get inside it wound drain out from the bottom of the handle? If you keep the o rings lubed spray and rain shouldn’t get inside as you only have 3 entry points on the light the switch which has a rubber boot, handle bottom and where the reflector screws on. It's a very sound design but doesn’t lend it’s self to being modded very easy [img]/ubbthreads/images/graemlins/banghead.gif[/img]

Later
Sway

Sway · #24 02-14-2004, 07:55 PM

Well here is a look at the beast, Version 6.357

This is the configuration I settled on as it still retains its ability to be powered from a vehicle or portable power source and have control over the 50W boost function (red rocker switch at the back of the light). I not very happy with the RatShack project box as they are not very durable but I can replace it in the future with something better I just need to do a little looking around.

Later
Sway

Jarhead · #25 02-14-2004, 09:42 PM

Man, thats just beautiful!

richpalm · #26 02-14-2004, 10:51 PM

Daaaayyyyyiiim!! Looks like a Nuremburg Party Rally from NS Germany 1938.

Of course, if you ever get tired of this thing, PM me first! [img]/ubbthreads/images/graemlins/grin.gif[/img] [img]/ubbthreads/images/graemlins/faint.gif[/img]

Rich

AlexGT · #27 02-14-2004, 11:39 PM

Take a look at the tree that is being illuminated with just the sidespill, that thing really rocks, Hey Sway are you gonna sell that mod or what? Stop teasing us and put a price tag on it!

I WANT ONE!!!!!

Alex

Sway · #28 02-15-2004, 02:46 PM

[ QUOTE ]
AlexGT said:
Take a look at the tree that is being illuminated with just the sidespill, that thing really rocks, Hey Sway are you gonna sell that mod or what? Stop teasing us and put a price tag on it!

I WANT ONE!!!!!

Alex

[/ QUOTE ]

Alex it's possible if I you could front me some money for a hair transplant, I don’t have enough left to pull out to build another. [img]/ubbthreads/images/graemlins/icon15.gif[/img]

OK maybe in the future if I ever get the bugs out of this one and pile up some test hours to see how dependable it going to be.

Later
Sway

Ginseng · #29 02-15-2004, 07:40 PM

Kelly,

That turned out to be a really nice piece of work. it looks like nothing else and performs like mad. Well done.

Wilkey

Sway · #30 02-16-2004, 03:45 PM

Thanks Wilkey!

I'm still tinkering with it now that I have decided to stay with this configuration. I can clean up my wiring harness and make it more compact and durable as there are 8 wires of various size with bulky connectors running from the project box up through the handle.

I got 30 minutes run time on 50W boost last night before it shut down from the jump starter which was not at full charge, nothing got hot and it ran perfect. I’m not sure what my new neighbors thought of the shaft of light coming from my garage but it was pretty with the snow falling. My 7.5 amp SLA from batteryStation was dropped off by the brown truck today [img]/ubbthreads/images/graemlins/smile.gif[/img] I’m topping it off now and making a lighter plug adaptor for it in preparation for a 35W run tonight.

Later
Sway