So the parts required to make this would be:
2C Mag
2x AW Protected LiIon C-Cells
Kaidomain reflector, bored to fit 5761
Kiu Socket
Borofloat lens
Philips 5761
I saw in your shootout you had some arcing problems with your 2C Mag61. Is this a common problem? Also are LiIons safe to run in these high out setups? I like the idea of running LiIon over NiMH as long as it's reasonably safe to do so.
Since that archived post I replaced the Kai reflector with LOP reflector by Litho, which is significantly better beam pattern and quality. I've actually pretty much rebuilt my entire hotwire collection -- I cannibalized all those ones in the beamshot thread. Eventually I'll do a new beamshot post but probably not for a while.
Also, I now believe the arcing was mainly a problem with that particular mag switch, since I've done other builds at >5A current, also through stock mag switches, without noticing the same problem. So if you were to wire one up as you described it should work fine.
A better approach that will require more work, if you're up for it, is to pass the current through a
Power Mosfet :
Pin 1 -- the "gate" -- connect the output of the magswitch to this. (
(EDIT: forgot to mentinon a large-value resistor between gate and ground is also needed))
Pin 2 -- source -- connect directly to the battery (+) contact
Pin 3 -- drain -- connect to the lamp socket
This is the simplest arrangement, and the biggest adavantage is a huge reduction in switch resistance. This part is only ~0.009 ohms, so for high current lamps, this will lead to a less voltage drop across the switch and brighter burning lamp.
I am in the process of converting most of my hotwires over to use transitor switches, with more complicated circuit controlling the gate so that I can add failsafes such as temperature probes with the ability to turn OFF the light if it's on and dangerously hot.
