Elzetta- The industry's best kept secret.

[Fuzzywuzzies]

Ran a batch of 6 more Nichia 519A conversions through this evening, both Bravos and Bones. Figured a few better, quicker and nicer ways of doing things, and by the last one it looked significantly better than factory. (Sorry, photos are of the first one!)

The first one I pulled to bits had some weird frosting on the original LED dome. Anyone seen that before / know what it might be?

Also, more photos because, well, more photos is better, right?

 

[Monocrom]

Fantastic job there, Fuzzy.

 

[scalpel_ninja]

@Fuzzywuzzies

Great photos of the mod! I'm planning to do the same for my first gen AVS head. Any tips? To what temperature did you heat the head? Does the retaining ring need to be removed? What did you use to pick out the glue? How did you keep the removal process clean?

 

[Fuzzywuzzies]

@Fuzzywuzzies

Great photos of the mod! I'm planning to do the same for my first gen AVS head. Any tips? To what temperature did you heat the head? Does the retaining ring need to be removed? What did you use to pick out the glue? How did you keep the removal process clean?

Thanks! Take it slow, there's no hurry. Let the heat do the work on the potting, you shouldn't have to pry forcefully on the PCB to loosen it. Some of them have hardly any compound, and come out really easily.
Be careful guiding the wires so they don't get scraped or damaged during removal of the old PCB and fitment of the new. Thoroughly removing the solder from the wires can help, as can chamfering the edges of the PCB wire let-ins on the new one.

You don't need to remove the retaining ring, it's easier to handle the head as a whole.
I have found it quite effective to rub or "roll" the potting compound while it is still hot, with your fingertips or a piece of rubber or fabric. Any remnants can be picked out with fine tweezers or scraped with a clean, sharp, flat-bladed screwdriver.

If you are using a copper PCB, I would recommend thermal paste to help reduce galvanic corrosion.
For cleanliness, use some planning and common sense, and keep your work area clean. If you heat the head to roughly 90°C (200°F), the potting compound loosens, but doesn't melt or become sticky. A little isopropyl alcohol never went astray in these projects either!
Also, tape a piece of cotton wool or similar over the LEDs to protect them until you're done.

Remember, we expect to see photos, or it didn't happen!

 

[aznsx]

@Fuzzywuzzies

Great photos of the mod! I'm planning to do the same for my first gen AVS head. Any tips? To what temperature did you heat the head? Does the retaining ring need to be removed? What did you use to pick out the glue? How did you keep the removal process clean?

I've been expecting a post like this from you for some time, just didn't know when it would come....

 

[scalpel_ninja]

I've been expecting a post like this from you for some time, just didn't know when it would come....

The Elzetta modification time did come, I just never posted about it. 😁 Here's my Alpha modified with a de-domed Nichia 519A 4500K. Final CCT as shown on the Opple reading with a pleasant, slightly warm and tiny bit rosy tint. With the hi/lo switch, it's easily one of my favorite lights.