"Cracken" - Quad XRE R2 Build Diary.

[gav6280]

So here it is after many, many months of faffing about.....

"Craken" an umbilical style scuba diving light machined from a solid aluminium billet.

Initial idea and design by myself.
CAD drawings by Alex Joyce.
Machining by www.duckworthandkent.net , Precision Engineers.
Technical input and general advice CPF's!

The Spec:

4 XRE R2 WG Led's - http://www.dealextreme.com/details.dx/sku.15943

Quad Optic - http://www.dealextreme.com/details.dx/sku.1915

Custom made 1200ma output Blue Shark Driver - http://theledguy.chainreactionweb.com/product_info.php?cPath=48_49_61&products_id=1136

O'Rings - http://www.polymax.co.uk/

6mm ploycarbonate sheet for lens - http://hub.shop.ebay.co.uk/

Will have a 3 cell Lithium polymer battery pack 5000mah- http://www.swanghobby.com/product.php?productid=1497&cat=14&page=1

So here's the good bit:

I am now going to send this off to a friend to be anodized in a heavy coating of matt black, whilst i build up the electronics.

As you can see this is just the head unit at the momment i am still formulating a plan for the battery cannister.

I would like a piezo switch but have no idea how to implment this?

I am hoping this design will surpass 100 Meters depth testing...

 

[gav6280]

Reserved.

 

[Packhorse]

So whats the beam angle of the optics like?

 

[steve6690]

I've tested that optic with 4 x Q5's and it was surprisingly good. It gives a nice narrow hotspot with a fair amount of spill. 4 of the cheapo 18.5mm dx reflectors seemed to throw more light though, with a slightly narrower hotspot. Interesting design though Gav, I think it'll have a bit of a military look after it's been anodised. Are you going to design a goodman handle for it ?

 

[aljsk8]

nice to see it done - seams like ages ago when i did the plans for it

how does it thread together is it smooth? does it have any play?
what about the seal - good?

looks just like the drawings - spot on

should be very nice when its done

did you get the battery canisters machined?

ill keep watching the thread

Alex

 

[MrSpock]

Fantastic! What kind of heat sink you are using?

Are you planning to batch-produce these? I'd buy one or two if they priced reasonably.

Cheers!

 

[gav6280]

So whats the beam angle of the optics like?

Not totally sure but would guess based on other peoples beam shots at around 8 - 10 deg. I will be sure to post some when it's done.

 

[gav6280]

I've tested that optic with 4 x Q5's and it was surprisingly good. It gives a nice narrow hotspot with a fair amount of spill. 4 of the cheapo 18.5mm dx reflectors seemed to throw more light though, with a slightly narrower hotspot. Interesting design though Gav, I think it'll have a bit of a military look after it's been anodised. Are you going to design a goodman handle for it ?

Not got a clue about a handle yet but i think im heading that way, or maybe a simpler stretchy neoprene band.

 

[gav6280]

Fantastic! What kind of heat sink you are using?

Are you planning to batch-produce these? I'd buy one or two if they priced reasonably.

Cheers!

No plans to yet but it's a possibility in the future.

As for the heatsink im not sure would have to go check the plans but i think it is a 10mm thick solid piece that press fits.

 

[gav6280]

nice to see it done - seams like ages ago when i did the plans for it

how does it thread together is it smooth? does it have any play?
what about the seal - good?

looks just like the drawings - spot on

should be very nice when its done

did you get the battery canisters machined?

ill keep watching the thread

Alex

Thread is very smooth indeed with absolutely zero play in it, but i think they did tweak it a bit from your original drawings.

Battery cannister has not been done as i am still not really sure what to do about switch....

It's not been depth tested yet, im still working out a good way to do it.

 

[gav6280]

Thought i would send it offer for a test in a marine engineers pressure pot and the result:

It leaked!

They made lots of recommendations though.


Put a step in the plastic lens so part of it is recessed in to the main body.

Add an O ring onto the new stepped part of the lens.

Remove the inside O'ring inside the top of lid piece.

Machine down main body front face O'ring groove so more of the O'ring is exposed

Reduce height of front lid section so as it screws down really tight
Thicker diameter O'ring on main body threaded section.


Dam what a pissa, and a major setback.

 

[Packhorse]

Bugger.
Oh well just think how good it will be once its finished!

 

[Flo1]

That's very disappointing!!

Did they say what pressure it leaked at?

 

[gav6280]

Yeah it got to 26 Meters. Im looking to get it to past 100.

 

[Flo1]

It's a real PITA when things don't go as they should!

What oring material are you using and are they thick enough?

 

[Lumenz]

Is this light called the "Cracken" or the "Craken"?

 

[SUBjohan]

Will have a 3 cell Lithium polymer battery pack 5000mah- http://www.swanghobby.com/product.php?productid=1497&cat=14&page=1

Is LiPo such a good idea:thinking:
what happens when you get a leak and saltwater creates a full short circuit over your LiPo pack. I mean pressure build up in a closed enviroment is :poof:deluxe.

I would go for LiMa or nihm.

Greetz Johan

 

[DM51]

Is this light called the "Cracken" or the "Craken"?

Kraken.

 

[steve6690]

Sorry to hear this bit of news Gav. I wouldn't take too much notice of the recommendations though. I use a commercially designed head with just one o ring and it's rated to 150m. You've seen pics of my other head design which is a very similar config to yours. Testing of that head is going fine. Its done 50m without a problem. What specification is the o ring that the "glass" presses against ? If you want to have a look in the flesh at either of the heads I have just let me know. They're both completely different designs so you might find something you like

cheers

steve

 

[J.D.]

Is LiPo such a good idea:thinking:
what happens when you get a leak and saltwater creates a full short circuit over your LiPo pack. I mean pressure build up in a closed enviroment is :poof:deluxe.

I would go for LiMa or nihm.

Greetz Johan

+1 on that...

or LiFe :o