CPF project light "Ultimate Nighthunter Dominator Killer" at 1500 lumens/1hour

[lemlux]

Re: CPF project light "Ultimate Nighthunter Dominator Killer" at 1500 lumens/1hour

Design Update:

I've decided that three battery packs aren't sufficiently comfortable. I will use only to 2 battery packs totalling 12 A NiMh 2100 mAh cells running serial / parallel at 7.2 V and 4200 mAh. At 7.9 oz @, the exta weight is also cumbersome. It's possible that raising the per cell amperage from 0.93 to 1.39 may drop voltage from 7.2 V to 6.9 V or 7.0. A drop to 6.9 V would cost 84 Lumens, but a drop to 7.0 would only cost about 40 lumens.

I've figured out how to avoid hose clamps and to provide a metal superstructure for mounting the Carley reflector. I went to Home Depot and bought several Simpson Strong Ties # I STA9 NER-443 in the hardware department. These are 1.7 oz galvanized rectangular strips that are 3/64" thick by 1 1/4" wide by 9" long with beveled corners.

I will sandwich (a)the two batteries in the rear 6" of the Strong Ties, (b)the 1 3/8" circumference 1" long Carley reflector at the front 1 1/4" of the strong tie, and (c)the bulb overhang, on-off switch, battery charging quick disconnect and other wiring in the 1 3/4" between the batteries and the reflector.

The Strong Tie has a centered 1/2" hole that is 2 1/4" to 2 3/4" back from the reflector end of the strip. This hole perfectly mounts a 0.8 oz Gardner Bender chrome plated toggle switch # GSW-125 and wire assembly that looks like a ball short-throw gear shift. The switch stands out 7/16" from the Strong Tie and has a nice positive feel to it.

These Strong Ties have five staggered holes in the rear 6" that I will use to lace the sandwiched battery packs firmly in place with parachute cord.

There are another two staggered holes in the front 1 3/16 " that I will use to wire wrap the reflector in place. The wire will also provide more opportunity to solder the wire / Strong Tie / Reflector surfaces together in a few places. The reflector will be recessed 1/4" from the front of the Strong Tie (d) to protect it and (e) to allow the reflector to be under both holes in the fron of the Strong Tie.

After all is together, I'll wrap the rear 6" handle portion. I'll use electrical tape first and enquire about wrapping a second layer with golf club grip tape.

When completed, these 550 L lights will be 9" long and weigh 18 oz plus the weight of reflector, tape, cord, bulb, and a little wire. I'm guessing 21 oz. The 7.2 V 4.2 Ah battery pack should run the 2.77 A bulb for an hour and a half.

For the time being, I expect to leave the front 3" of the light exposed and air cooled. It won't fit into 2" copper pipe, but I might someday try to find 2 1/4" or 2 1/2" copper pipe to enclose the front and provide a Pyrex lens.


Material costs are modest:

Surplus battery packs: $ 2.00 * 2
7.2 W 2.77 A 553 L W/A bulb: $ 7.50
Carley Set Screw Reflector $ 4.81
Carley bulb sleeve $ 1.00
Strong Ties (2@) $ 0.37 * 2
Gardner Bender Toggle $ 2.95
Tape, Wire, Quick Disconnect $ 2.00

Total Materials $23.00

So it should cost $23 plus tax and some shipping for the materials for the first three I build. (I've bid $25 on a lot of 10 more battery packs, so the next five lights would cost at $1.00 more.)

 

[brightnorm]

Re: CPF project light "Ultimate Nighthunter Dominator Killer" at 1500 lumens/1hour

lemlux, Klaus et al:

Do you anticipate selling these and other high lumen originals to Flashaholics and others?

If you work up to "consumer's models" I would be very interested in buying one/some.

Brightnorm

 

[bwcaw]

Re: CPF project light "Ultimate Nighthunter Dominator Killer" at 1500 lumens/1hour

I am sure that many cpf'ers would gladly
hand over their hard earned cash for one of those lights. I know i would rather pay $75++
for one that is already assembled than make
my own. I hope you do sell these lights!

 

[lemlux]

Re: CPF project light "Ultimate Nighthunter Dominator Killer" at 1500 lumens/1hour

BigWuss and BrightNorm:

Aragorn tells me that nobody will want to buy an ugly light that isn't fully enclosed, doesn't have a lens, and isn't even slightly water resistant. I figure that something with (1) the 500 L power of an M6 that (2) will run for 1 1/2 hours, (3) which will structurally hold together if you keep it out of the rain (4) that weighs "only" 21 oz., (5) is a relatively small 9' long by an almost square 1 1/2" width and height has more than trivial useability.


I'm impressed by the elegant work of Messrs. Ramsey, Lambda and others who fit something technically advanced into an OEM light. I hope to approach temperature-safe 300 L from above and below 300 L in Energizer Double Barrels with Carley aluminum reflectors. I hope that the DB projects might wind up being considered as attractive and worthy of a beginning apprentice of CPF's stars. I am not technically advanced or particularly electrically savvy. I just salivate over playing around with available brute force components that can make an ergonomically pleasant flashlight -- It merely has to be easier to hold and use than a lantern (oh yeah -- and bright, too.).

What I don't know, is how many crazies besides me think it would be fun to play with a small 500 L light that looks like the semi-finished product of a rough carpenter. Did the two of you consider the exposed bulb and reflector? If so, how much does it bother you? (I could try to sell you by observing that the 12% light loss from a lexan lens is worth 60 lumens on this light.)

For no more than two of you who might want to build your own, there remain two unbid lots of 10 battery packs at an opening bid of $25.

http://cgi.ebay.com/ws/eBayISAPI.dll?ViewItem&item=134902620 8&r=0&t=0&showTutorial=0&ed=1020104356&indexURL=0&rd=1

I say "no more than two" because Adam S and I have each submitted $25 bids on the other two of four lots. The auction ends at 11:19 PDT tomorrow. If people outbid me I won't have any to sell. My two kids and I will each get one of the first three.

 

[lemlux]

Re: CPF project light "Ultimate Nighthunter Dominator Killer" at 1500 lumens/1hour

Auction update:

I was busy today and didn't see two bidders jump in the last 10 minutes to take 3 of the 6 battery pack lots of 10 packs. At least Adam S was able to get his battery.

Unless I find more packs, the three 500 L projects will stay in the family.

 

[Graham]

Re: CPF project light "Ultimate Nighthunter Dominator Killer" at 1500 lumens/1hour

Here's a quick update on my monstrosity..

So far, I have 2 x 7.2v 2.4ah RC packs, and have used the standard RC battery connectors to make a wiring system which allows me to unplug each pack so it can be recharged in a standard Tamiya smart charger (much cheaper and easier for me than designing/building my own..)
I have wired in an on-off-on rocker switch - one position will be for the main halogen lamp, the other position will be for the 2 LS emitters I will be adding.

The problem until now has been a case - I don't have any access to decent raw materials(and tools!) for making a custom metal case, so I've had to look for a cheap existing one which would fit the 2 RC packs.
I ended up with a cheap $7 plastic lantern originally intended for use with those largish 6v lantern batteries. The 2 RC packs fit in nicely, with a little padding to stop movement. The large lantern-sized reflector bay is big enough to have the MR16 lamp on top with 2 LS emitters below.

At this point, I have removed the original switch and drilled out space for the rocker switch I am using, and have made an aluminium bracket to mount the MR16 socket in the correct position. I have had to drill holes in the case to mount it using bolts, but this was never intended to be waterproof or anything, so I'm not really worried.

Next I will be making a bracket to mount the LS emitters. For now, the LS units will be run using a basic voltage drop resistor, to run them from the 15v or so supplied by the battery packs. Given the amount of power the RC packs can supply, I'm not overly worried about efficiency for the LS units at this stage.

Next weekend it should be in a near-finished state, so I will post some pictures. It won't be pretty, but functional. My aim for this is a 'proof of concept'. Later when the opportunity presents itself I may make a better, custom case for it..

Graham

 

[brightnorm]

Re: CPF project light "Ultimate Nighthunter Dominator Killer" at 1500 lumens/1hour

Originally posted by lemlux:
BigWuss and BrightNorm:

I am not technically advanced or particularly electrically savvy....

What I don't know, is how many crazies besides me think it would be fun to play with a small 500 L light that looks like the semi-finished product of a rough carpenter.....[/QUOTE

Lemlux,

I am very interested in a finished, enclosed,
bug free and relatively idiot proof product
that has specs/capabilities not currently available commercially, and I'm willing to pay any mutually determined reasonable price for it.

If such a light is produced by anyone in our group, I believe that he should protect himself legally before selling it to me or anyone else, because such a creation would probably have commercial possibilities.

By the way, if you aren't "technically advanced or electrically savvy", I hate to think what that makes me!

Brightnorm

 

[lemlux]

Re: CPF project light "Ultimate Nighthunter Dominator Killer" at 1500 lumens/1hour

Graham:

Appreciate the update. How strong is the glass on the MR16 reflector? My local surplus shop has 20W and 45 or 50 Watt MR16's on sale for $2.00 @, but I have no feel how much punishment they'll take. (Klaus had to explain to me that the reflectors were glass, not some super plastic.)

In my project, the reflector will be as significant structural member. I do look longingly at the compact MR16, however. I don't have a good idea how to mount it.

BrightNorm:

No false modesty in my comments. I can use algebra to figure out various volts * watts * amps relationships. I can look at Brocks's tables and read Klaus' comments and get a reasonable feel for interpolating what the voltage drop at various drain levels on various battery chemistries may look like.

I can look at Welch Allyn's tables and understand that for each 10% a bulb is driven over or under from it's design voltage it will increase or decrease roughly 30% in output.

I can't design a circuit, but I'm increasingly able to appreciate what the circuits discussed by the cognescenti on this board are capable of performing.

I appreciate your comments and may, one day, come up with a weather resistant package. As I said before, I feel like a kindred spirit of all of us hermit crabs in search of a better shell to put cobbled goodies into.
I'm a scrounger who gets off on the "Eureka!" feeling of thinking "Say, I know what I might connect that to......"

 

[Graham]

Re: CPF project light "Ultimate Nighthunter Dominator Killer" at 1500 lumens/1hour

<BLOCKQUOTE><font size="1" face="Verdana, Arial">quote:</font><HR>Originally posted by lemlux:
Graham:

Appreciate the update. How strong is the glass on the MR16 reflector? My local surplus shop has 20W and 45 or 50 Watt MR16's on sale for $2.00 @, but I have no feel how much punishment they'll take. (Klaus had to explain to me that the reflectors were glass, not some super plastic.)

In my project, the reflector will be as significant structural member. I do look longingly at the compact MR16, however. I don't have a good idea how to mount it.
<HR></BLOCKQUOTE>

I'm not sure how strong it is, but I suspect it is designed more for heat resistance than impact resistance. Also, there is bound to be variation between manufacturers. In addition, I have seen some which have a slightly curved lens, although most are just flat. For my light, I will eventually have an additional lens covering the whole assembly because I am using an existing lantern case.
However, I think you can rely on the MR16 lens itself without too many problems..(but I wouldn't expect it to stand up to being thrown around or anything..)

Graham

 

[snake]

Re: CPF project light "Ultimate Nighthunter Dominator Killer" at 1500 lumens/1hour

Hello Lemlux,
during the labour day holiday, I try out the glass reflector. this is an Osram decorative bulb 12V 35W with glass reflector 10degree beam, 35mm diameter. M16 is 50mm right ? it could fit in the DB 4AA head just left a few turns aways from totally close. the problem is the glass reflector is not reflective as the DB reflector, even it is 12V 35W (I drive it with a transformer which used for a 12V 50W bulb) it is not bright as my 6V 10W bulb in the DB!!

I think the reason is the glass refector is glass! it is too transparent, I can see the image of the bulb at the back of the reflector when the light is on.. so the side and the back of the bulb light up as well..

too bad.. if it works I just insert some insultate ring (used on some switch)on top the socket then finish my DB 4AA upgrade..
still looking for reflector..may be just buy a UK light cannon ..

 

[lemlux]

Re: CPF project light "Ultimate Nighthunter Dominator Killer" at 1500 lumens/1hour

Graham and Snake:

I just learned that MR16 stands for lamp assemblies with "Mirrored Reflectors" (MR) that have an OD of 16/8" or 2" or 50.8mm The other MR number designations all refer to the number of eighths of an inch of diameter.

Snake: I doubt you can close down on an 2" MR16 in the DB because the DB reflectors are are closer to 1 7/8" diameter.

I haven't bought any to play with. I'm waiting to find out (a) if W/A will sell bulbs with longer pins or (b) if Carley will be willing to remove about 3/16" of solid from the back of their 1 3/8" diameter 1" long reflector. The sample I got wasn't the set screw version, so I don't know whether the set screw will still work if 3/8" is removed.

 

[snake]

Re: CPF project light "Ultimate Nighthunter Dominator Killer" at 1500 lumens/1hour

Yes Lemlux,
MR16 did not fit in DB not just diameter as well MR16 is too tall, so I focus on MR11, it fit quite good.

the good of MR is prefocused, the bad is most MR11 come with "transflective" reflector not aluminium reflector, lots of light come out at the rear.. I could only found "reflective" reflector with MR16..

 

[fracman]

Re: CPF project light "Ultimate Nighthunter Dominator Killer" at 1500 lumens/1hour

I haven't followed this closely, but count me in.... if there is something to be counted in for!

 

[lemlux]

Re: CPF project light "Ultimate Nighthunter Dominator Killer" at 1500 lumens/1hour

My Carley reflectors are on order, and I will make some 3 * 7.2 V battery pack flashlights as described above, but with 6.0 V 3.35 A bulbs overdriven to about 6.8 V and 600 Lumen. Also, Quikaluminum epoxy putty should simplify the task of stably bonding a round reflector to flat galvanized strips on the top and bottom.

I have just started on a super lantern that should be in the 1500 to 2000 lumen range. It is feasible because I still have lots of surplus 7.2 V battery packs that can be ganged into 14.4 V serial / parallel packs.

I now have many of the parts for what will be an expensive but exceptional hand held lantern. I today bought a PIAA 540 off road running light kit. Two lamp assemblies and wiring harness and switch. Lamp is the PIAA 55 W "Extreme" bulb that supposedly is equivalent to normal halogen 110W H3 bulbs. ( Note" I have PIAA 55 W H3 "Platinum" bulbs in the high beams of my car that are supposed to be equivalent to 85 W normal Halogen bulbs, and they are quite bright. In fact, they are bright enough and white enough to nicely complement my HID low beams.)

The well heat-sunk 940 aluminum reflector steel housing lamp has a 15 degree circular "pencil beam" and is about 5 1/8" diameter and 2 1/2 " deep.

http://www.piaa.com/displayLamp.php3?inc=540.html

I will run one of these with 8, 10, or 12 of my 7.2 V 2450 mAh A NiMH battery packs wired in serial / parallel 14.4V. That will give me either 9.6 Ah, 12.05 Ah, or 14.5 Ah for 14.4 V or double that for 7.2 V. At 4.58A drain, that should give run times of from 2 hours to 3 hours. Much of this run time should be over 13V and would be much brighter than using a 12V SLA battery. I have to make weight vs.. voltage drop and run time tradeoffs. I suspect most of the time of commercial H3 spotlights and small 2.5 to 4.0 Ah SLA batteries are run at < 12 V.

The 7.2 V packs packs weigh 8 oz each. I will wire a switch so I can toggle between 14.4 V and 7.2 V. At 7.2 V I can charge all the packs in parallel at 4.5 A with a charger jack.

After I receive my Carley reflector order, I will install a LOLA. I can overdrive a "little" 6.0 V 3.35 A W/A 01111 bulb at about 650 Lumen. My 650 Lumen LOLA would have 2.7 times the run time of the 540. The voltage toggle wiring will protect me from lighting either lamp at the wrong voltage.

I have a 7" tall by 5" wide by 3" long RS project box that will hold 12 @ 7.2 V battery packs before consideration for mounting hardware , wiring, & switches. I'll figure out where to mount an exosceletal backbone across the top to downward mount a 540 lamp and a substantial, comfortable lantern grip handle with at least a 5" grip.

I might eventually hang one or two 5W LS along with whatever current limiting circuitry CPF'ers subsequently develop onto this box to give me a dimmer secondary 120 Lumen, long life close-in area flood light LOLA for the 7.2 V circuit.

Total weight will be < 10 pounds.
Longest length will be about 6" (3" box + 2 1/2" lamp + 1/2" ventilation gap.
Longest depth will be about 9" (7" box depth plus 2" handle height)
widest width will be about 5 5/8" the widest point of the lamp.

The 2" wide 1.3" deep reflector LOLA can be mounted above the HOLA on or next to the handle.

Total out of pocket cost before the 5W LS is in the neighborhood of a Light Canon.

 

[Klaus]

Re: CPF project light "Ultimate Nighthunter Dominator Killer" at 1500 lumens/1hour

LOL - it must be lemlux when a 5W LS is talked about as a LOLA

Klaus

 

[lemlux]

Re: CPF project light "Ultimate Nighthunter Dominator Killer" at 1500 lumens/1hour

Klaus:

Actually, I imagine the 5W LS as the secondary LOLA at 1/5 the brightness of the primary LOLA. The primary LOLA, in turn, should be 1/3 to 1/5 the brightness of the HOLA.

Some road debris broke one of the auxiliary PIAA running lights on my car. A single light costs about 60% of the cost of two lamps plus wiring harness and switch, so I justified 60% of the expenditure as car maintenance and 40% as flashaholism.

 

[lemlux]

Re: CPF project light "Ultimate Nighthunter Dominator Killer" at 1500 lumens/1hour

Rather than use up so many of my 2450 mAh 7.2V battery packs, I'm bidding on some 3000 mAh 7.2 V sub C packs. The 20A max drain design of these cells with average output of 1.15 V per cell makes me think that I can have a much lighter serial 2-pack for the 4.58 A drain of the PIAA 540 lamp. The main reason I planned to use 8 to 10 of the 2450 packs wasn't run time, but a desire to avoid excessive voltage drop at the 4.58 drain.

My immediate trade of 6@ 2100 mAh 7.2 V A packs to Snakebite for 6 # 1800 mAh 6.0 V 4/5 A packs for use 10 cells to a DB8AA convinced me to go this way. I'll conserve my 2450 mAh packs for use doubled or tripled up in parallel on 6.0 V to 6.3 V project lights drawing 3.35 A or less.

Sub C NiMH's are specced to weigh between 55 and 62 grams each compared to A NiMHs that weigh 40 grams each. Thus, 2 @ Sub C packs will weigh only slightly more than 3 @ A packs. The two packs should be slightly more than 744 grams or 1.6 pounds and should run the PIAA 540 for just under 40 minutes.

 

[Klaus]

Re: CPF project light "Ultimate Nighthunter Dominator Killer" at 1500 lumens/1hour

@lemlux,

here Sub-C Test and stuff you´ll find a sh*tload of info on variuos SUb-C cells, their voltage drop behaviour under load and all that.

regards

Klaus

 

[lemlux]

Re: CPF project light "Ultimate Nighthunter Dominator Killer" at 1500 lumens/1hour

Klaus:

Thanks for the chart. All of those cells delivered at least an average of 1.06 V at 20A, so any should be good for my application. This will be bright enough on the high output automotive running light.

 

[Nerd]

Re: CPF project light "Ultimate Nighthunter Dominator Killer" at 1500 lumens/1hour

I remember seeing that Osram has a model with 12V 50Watts 10 degree beam. Now now, that is a light you shouldn't go around shining in people's faces.

Anyone has any new ideas or updates to contribute?