LED_ASAP
Enlightened
A fellow CPFer burned the miniature halogen bulb in his SureFire G2 when he put a Pila battery in the light. Instead of getting a replacement P61 lightbulb assembly for $25, he asked me if I could mod the G2 into a Luxeon light while maintaining the modular design of the P61 assembly.
The P1 lightbulb assembly has a reflector made of pure aluminum which is about 1mm thick around the lip and maybe 3mm thick towards the bottom. A short cylindral portion at the base of the reflector connects the reflector to the plastic base of the assembly by epoxy. Two springs connect the halogen bulb to the battery.
After some serious head scratching /ubbthreads/images/graemlins/thinking.gif I finally got a plan.
The epoxy-sealed parts were separated by brutal force /ubbthreads/images/graemlins/naughty.gif
A ~1cm section of a 9mm-diameter aluminum rod was cut out. Two 1mm holes were drilled on the slug length-wise, about 0.5mm from the edge (had anybody else tried to drill similar thin, long holes with just a hand drill? I had to repeat a few times and nearly broke my drill bit, before finally got a piece that didn't have the hole poking out half way down the length.) The holes were lined with a plastic sleeve; two wires were threaded through; the Luxeon emitter was mounted on the slug by epoxy, and connected to the wires.
The opening of the reflector was enlarged to accomodate the slug.
The Luxeon was connected to a bentch supply and the reflector was put on. After finding the appropriate focal point, I scored a mark on the slug, and it was shortened so that it could sit flat at the focal point.
I used the Buck converter described in the DN-73 design sheet. Of course the parts were changed.
The Luxeon slug was epoxied to the back of the converter board:
Then the reflector was epoxied on:
The two springs were put in place:
Please note the plastic ring between the two springs---it was used to help the final epoxy-seal process.
Here is the final assembly---epoxy was poured in, and the springs were soldered to the board.
The module goes into SureFire just like the original module, and should work with any light that accepts the P61 assembly.
The beam shot---the second is forced -2 level under-exposure. There are some small "buds" at the rim of the beam, which are caused by plastic nipples on the SureFire G2 bezel.
The emitter was a TV0J from Klaus, and the driving current was at 1A. The "orange peel" reflector was not the most effective in generating a super-bright hotspot, but it does generate a flood of light with a tight hotspot. The throw was pretty good---easily reached 30m+ at night. Sorry I don't have any "standard" high-powered light to compare the beams /ubbthreads/images/graemlins/icon3.gif
The P1 lightbulb assembly has a reflector made of pure aluminum which is about 1mm thick around the lip and maybe 3mm thick towards the bottom. A short cylindral portion at the base of the reflector connects the reflector to the plastic base of the assembly by epoxy. Two springs connect the halogen bulb to the battery.
After some serious head scratching /ubbthreads/images/graemlins/thinking.gif I finally got a plan.
The epoxy-sealed parts were separated by brutal force /ubbthreads/images/graemlins/naughty.gif
A ~1cm section of a 9mm-diameter aluminum rod was cut out. Two 1mm holes were drilled on the slug length-wise, about 0.5mm from the edge (had anybody else tried to drill similar thin, long holes with just a hand drill? I had to repeat a few times and nearly broke my drill bit, before finally got a piece that didn't have the hole poking out half way down the length.) The holes were lined with a plastic sleeve; two wires were threaded through; the Luxeon emitter was mounted on the slug by epoxy, and connected to the wires.
The opening of the reflector was enlarged to accomodate the slug.
The Luxeon was connected to a bentch supply and the reflector was put on. After finding the appropriate focal point, I scored a mark on the slug, and it was shortened so that it could sit flat at the focal point.
I used the Buck converter described in the DN-73 design sheet. Of course the parts were changed.
The Luxeon slug was epoxied to the back of the converter board:
Then the reflector was epoxied on:
The two springs were put in place:
Please note the plastic ring between the two springs---it was used to help the final epoxy-seal process.
Here is the final assembly---epoxy was poured in, and the springs were soldered to the board.
The module goes into SureFire just like the original module, and should work with any light that accepts the P61 assembly.
The beam shot---the second is forced -2 level under-exposure. There are some small "buds" at the rim of the beam, which are caused by plastic nipples on the SureFire G2 bezel.
The emitter was a TV0J from Klaus, and the driving current was at 1A. The "orange peel" reflector was not the most effective in generating a super-bright hotspot, but it does generate a flood of light with a tight hotspot. The throw was pretty good---easily reached 30m+ at night. Sorry I don't have any "standard" high-powered light to compare the beams /ubbthreads/images/graemlins/icon3.gif
