DIY Smaller than Larry Light CR2: A 14250 light measures 49.5x16.5mm

[ma_sha1]

For those of you being around CPF long enough, Larry light needs no introduction.
For those of you that are new & not aware of Larry Light, this thread will help.
http://www.candlepowerforums.com/vb/showthread.php?t=97749

Simply put, Larry Light CR2 was the original smallest CR2 sized light & was cloned several times over the years, including some well know CR2 lights such as CR2 Ion, CR2 Aeon & Nitcore EZ CR2 etc.

Each time it gets cloned, it seems to gain some weight .

Larry Light CR2: 50.4mm x17.07mm (in the avatar of tvodrd
CR2 Ion & CR2 Aeon: 55mm x 18.5mm, gained a little in size
Nitecore EZ Cr2: 63mm x 17.5mm, gained more in length

These lights remains similar looking, with head & body separated by
a brass ring. This is the look I need to stay with.

Now, with the new release Tank 007, at 85mm x 16.5mm with a look
that fits the bill of Head & body being separated by a brass ring,
I can finally start this chop-job project:

With the max diameter (at bezel) being only 16.5mm, all I had to do is to cut it short, sound easy enough, right? My plan is to cut it down & direct drive with 14250 Li-ion, technically it's not a CR2, but close enough, don't you think?


OK, let's get started.

Cut down the tube & re-connect the tail end, then open up the head:

Now, after wiring DD to by pass the driver, the stock led "Golden dragon" turned angry blue under 14250, so I swapped in a XPG-R5 on trimmed 10mm squae board (XPG on SQ board is 1mm thinner than the round board, every mm counts!)

When I put everying back together, it measured 59mm x16.5mm,
not too bad, already passed one clone, the EZ Cr2.

The beam shot is pretty typical XPG, with larger hot spot.

However, still a long way to go to the goal of 50.4mm
So, more cutting to come!

 

[ma_sha1]

Re: DIY Attempt smaller than Larry Light CR2

Reserved for: cut-her-down, chop job continues...

I found a shorter reflector, shorter by ~ 4mm.

First, grind down the Bezel as well as the copper threads on the "neck' section of the flashlight that went into the bezel,
both by 4mm. The Grinding leaves rough marks after done.

But that can be cleaned up with Knife Sharpening Stones under running water by hand, now it's clean:

Front section of the inside threads need to be trimmed away, first attempt with step-drills.

The step drill didn't work very well as the step is too close to the OD of the bezel.
But I was able to cut the threads away with a steel hobby knife like this:

After I put the head back together, I was able to shorten the head by ~4mm vs. stock.

Now, Finished light (Right) vs. Stock light on the left.
I am at 55mm even. Think Aeon? :wave:

The light is 55mm x16.5mm in size, officially surpassed CR2 Ion & Aeon. (55mm x 18.5mm).
However, I am still 4.6mm away from Larry Light :tsk:

I need to find a way to chop it further, this is not the end...

 

[greenLED]

Re: DIY Attempt smaller than Larry Light CR2

Nice project, ma_sha1.

 

[ma_sha1]

Re: DIY Attempt smaller than Larry Light CR2

Thanks, greenLED,

4 hours of work for a gain of 4mm, at 1mm per hour, slower than snail

 

[greenLED]

Re: DIY Attempt smaller than Larry Light CR2

:thinking: ...how much thinner can you get the emitter board by sanding it?

File the tail end down a bit?

If I were familiar with the 007, it'd be easier to make other suggestions. Sorry.

 

[ma_sha1]

Re: DIY Attempt smaller than Larry Light CR2

You read my mind, greenLED.

I have been busy grinding the bottom side of the brass tube whole afternoon, was able to grind away
~5mm to expose the bottom of the driver. Also had to grind down the battery tube until "TANK" become "IANK"

Putting it back all together, amazingly small:

Still working

The moment of truth: Did I do it?

I think so, 50.4mm x 16.5mm, Yeah!!! :rock::naughty:

 

[greenLED]

Re: DIY Attempt smaller than Larry Light CR2

I bet you can find an extra 0.1mm to shave off. :nana:

:twothumbs

 

[ma_sha1]

Re: DIY Attempt smaller than Larry Light CR2

OK, sounds like a challenge, How about a final shave of 0.9mm off instead?

At 49.5mm x 16.5mm in its final form, it's now shorter than the AA battery (AA=50mm even) :laughing:

 

[greenLED]

Re: DIY Attempt smaller than Larry Light CR2

OK, sounds like a challenge, How about a final shave of 0.9mm off instead?

(I'll shut up now.)

At 49.5mm x 16.5mm in its final form, it's now shorter than the AA battery (AA=50mm even) :laughing:

:rock: :rock: :rock:

Nicely done!!

 

[SFG2Lman]

awesome work, an excellent show of what can be done with some elbow grease and an audience lol

 

[ma_sha1]

LOL, had not been the greenLED, could have been full of elbow grease with no audience :laughing:

awesome work, an excellent show of what can be done with some elbow grease and an audience lol

 

[ma_sha1]

After swap in the shallow reflector, I am not happy enough with the beam,
it's got a center dark void that I couln't get rid of. So, I've been playing with some small & shallow optics & try to find one that works with this XPG in 14mm diameter. (I tried 5-6 optics, ranging 13 to 17mm in diameter) They are very cheap from mouser.

This is the one I settled with: "DBM Reflecx: LED Lighting Optics OSRAM Golden Dragon Very Narrow 14.5mm" Part#; 735-0-005s. After some slight trimming, it fits in pretty well. Note that original Larry light CR2 also used optics (cut down Fraen LP or NX05 usually with LuxIII) .

Beam shot:

Here is a beam shot of larry light CR2 I dug up from a real old McGizmo thread:
http://www.candlepowerforums.com/vb/showthread.php?t=34632

Interestingly, the two beam style looks kind similar, both have round hot spot & some what squarish corona.

 

[greenLED]

LOL, had not been the greenLED, could have been full of elbow grease with no audience :laughing:

Actually, ma_sha1 highjacked my account and was replying to himself.

Nicely done, ma_sha1!

 

[ma_sha1]

Actually, ma_sha1 highjacked my account and was replying to himself.
Nicely done, ma_sha1!

That's Funny, greenLED. Actually, if I had the power to highjack, don't you think I'd be hijacking McGizmo account instead? channel some of those Ti funding & wind up in Hawaii myself?

 

[greenLED]

Agreed.

 

[ma_sha1]

Just picked up some Nitecore EZ lights during 4 Sevens Blow out sale,
can't resist to post a family Photo, the Larry Light clone makes the
EZ CR2 & EZ123 looks like giants.

 

[greenLED]

If you file the knurling, you can make it even thinner.

 

[Radio]

I think Larry would be proud. :thumbsup:

Good job!

 

[matrixshaman]

Nice work and a real reminder of the spirit of CPF I miss at times :thumbsup:

 

[pmoore]

Nice job!!

Paul