1765 Lumen P60 Quad XPG Silver Plated Copper Heatsink Direct Drop-in, in developement

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Ok, I have everything now except the driver parts, they should be here any day, this should all come together quite quickly now.

The unique spring design worked well with the spring steel, but once I got the beryllium copper, not quite as well, I didn't like how fatigued it became when I bent it into shape.

So, back to more of a standard spring similar to the drop-in I sent Kestrel, but it doesn't retract inside the drop-in, I wanted to preserve as much thermal mass as possible.

The good news however, is that it fits great, with no gap in my genuine 6P.

I've also completed a silver plated copper drop-in, minus the driver. There were a few processes I was sure would work in it's customized construction, but you never know until you actually follow through. Glad to report it all went very well. It's in front of me right now.. and I can't really stop looking at it.

While I'm waiting for the drivers I'll get work work pumping out some heatsinks, so I'll be ready when they get here.

Sales thread coming soon.
 
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Can't have a perfect fit on L2 and the 6P, L2 has a larger diameter drop-in well. I will make an insert to add the taper to the L2 that the 6P has so the spring will work properly, and then some copper tape around the outside to take up any gap.

I haven't used this copper tape myself, but other say it works.
 
VanIsleDSM said:
While I'm waiting for the drivers I'll get work work pumping out some heatsinks, so I'll be ready when they get here.

Sales thread coming soon.
Click to expand...
Sounds awesome. :thumbsup:

2 questions regarding drivers,
  1. Is there still going to be the configuration flexibility of the driver: (i.e. 1, 2, or 3 output modes with no strobe or SOS?
  2. Will there be a future possibility of a 2x LiIon unit? It seems to me that if absolute maximum outputs are desired (as mentioned earlier in the thread), 7.4 Vin would facilitate that - although if there isn't an available driver, then a 2x LiIon unit just wouldn't be possible.
Very interested and looking forward to the final result on these. 🙂
 
Yes!

Any drop-in will be available as,

5 mode: High-Med-Low-Strobe-SOS
3 mode: High-Med-Low
3 mode: High-Low-Strobe
2 mode: High-Low
1 mode: High

No plans for a 2x Li-Ion unit right now. You can get full output from 1 Cell.
 
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Do you happen to know what type of beryllium copper alloy you have and if it has been heat treated? You might not be using the right material for the job, if you are still interested in this material at all. I understand your thinking though, since beryllium copper can have a conductivity almost as high as pure copper.

You're welcome for the wire. 🙂
 
C172 beryllium copper, for springs. Trying to obtain what temper it is, information isn't available. It'll be 1 of the 19 different tempers for C172 though... haha.

I am still using the beryllium copper, because of how much better it conducts than spring steel. Spring steel is about as electrically conductive as it is malleable.

There might be a better temper, closer to spring steel, but I bet the conductivity would go down. Either way, I'm happy with the design now. Kestrel's initial fitment problems with the drop-in I sent him led me to consider other options for ground connection, but I pretty much ended up right where I started, I think it's the best all around design for electrical contact, fitment, and durability. While my "spider spring" as I was calling it would have provided somewhat better electrical contact, I think durability would have probably suffered, and if I went to a harder temper C172 I'd just lose the extra conductivity and end up building a more elaborate spring for nill.

Working with ~5A you really have to pay attention to this stuff, as it would be pretty easy to have more voltage drop in the switch and contacts than in the LED driver itself.

Whenever I've got some time waiting for parts I've been working on the FET clickie switches, which I think I'll call FETties. Been testing different MOSFETs and such, and have found the winner. FETtie will also have a beryllium copper spring and gold plated contacts for the retaining ring and the battery.

I plan to do some tests at 5A with some different switches if I can get accurate results. The FETtie's FET will have an extremely low on resistance of 2.6milliohm. At 5A this will mean a voltage drop of 0.013V. I'd expect to see more than 10X that from a cheapo clickie.. resulting in noticeable run-time degradation. This is speculation however.. I will check it all out when the FETties are complete. One thing for sure though, they will definitely outlast any regular clickie, with the current being switched by a solid state semiconductor vs. a mechanical contact.
 
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VanIsleDSM said:
While I'm waiting for the drivers I'll get work work pumping out some heatsinks, so I'll be ready when they get here.

Sales thread coming soon.
Click to expand...

Yes! But please put people that wanted one from this thread on top of your list. It would be very disappointing to the people that said they wanted one here, only to miss the new sales thread for a day or two and you ran out of drop-ins. Happened to me before and it sucked 😕
 
Very interested in this. It is cool to see the development that goes into this module. When those lucky enough to get one use it they can refer to the thread for every detail that went into making it. I hope I am one of the lucky ones because I believe these will go fast. :thumbsup:
 
kodama said:
Yes! But please put people that wanted one from this thread on top of your list. It would be very disappointing to the people that said they wanted one here, only to miss the new sales thread for a day or two and you ran out of drop-ins. Happened to me before and it sucked 😕
Click to expand...

When I make the sales thread I'll go through this one, and in order add everyone who expressed interest to a reserve list for a couple days to give them first chance.
 
I hope you will consider and accept money order as one other method of payment when your drop in will be available.
 
All of the payment and price stuff will be for the sales thread.. This one started out as a development and I'd like to keep it on track. As edelbrock mentioned, it'll contain a lot of detailed information about the drop-in for those that have one.
 
Hmm, almost makes me regret buying an M61...at least until the runtimes smack me upside the head, but I guess that's what the low mode is for 😛
 
Yeah.. that's the thing with something with such high power capability, on medium it'll be putting out 35%, a pathetic 617 lumen with 2A draw for the 1400mA unit, and 520 lumen with 1.5A draw for the 1050mA unit, so you get good run time and output... and you have that 100% high for when you want it :devil:

Rough figures obviously, but either way, this quad on medium will slaughter your standard single die emitter with only slightly more drive current.

I have a few, but thought I'd make another LED order so I have a half decent amount when everything kicks off.

I've got,

R5 Flux 6300K 1C Tint

R4 Flux 4250K 5B1 Tint (I love these, my they'll be in my personal Quad)

Q5 Flux 3000K 7D2 Tint (Not a yellow overload like some warm white, lots of red)

If someone has some of their own XPGs, or know where to get a specific bin they want, I can order and use them if desired.
 
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