Hi,any opinions on this?

[Erilaz]

Materials: aircraft grade aluminium, plastic and miscellaneous O rings.

Parts list:

1x O-ring , ID=42.0x3.0mm Perbunan, goes on top of the lens.
Würth O ring:
ISO 3601 Perbunan70 metric
RG-O-ISO3601-PERBUNAN70-42,00X3,00
Art.-no. 046804230
https://eshop.wurth.co.uk/O-ring-metric-RG-O-ISO3601-PERBUNAN70-4200X300/046804230.sku/en/GB/GBP/

Lens:
http://www.international.mtnelectronics.com/index.php?route=product/product&path=68_70&product_id=70

Reflector:
http://www.international.mtnelectro...te=product/product&path=68_101&product_id=495

LED:
Cree XLamp XHP70.2 LED colour Warm White
2600 ~3700 6Volt version,20mm: Copper Direct-Thermal-Path.
http://www.international.mtnelectro...te=product/product&path=60_114&product_id=867
That is placed on a machined "shelf" below the reflector. It provides cooling as it conducts heat to the flashlight head.

LED driver:
https://led4power.com/product/ld-b4...ed-flashlight-driver-external-mosfet-support/
Goes in the plastic holder, fastened with glue.
This driver does not have reverse polarity protection. It should be possible to fix that using a rectifier diode that tolerates 5Amps, connected in series between one of the switches legs and chassis/endcap. The holder can accommodate a driver up to 20mm diameter.

2X O-rings ID= 28.0x3.0mm Perbunan, goes in the battery compartment top and bottom.
Würth O ring:
ISO 3601 Perbunan70 metric
RG-O-ISO3601-PERBUNAN70-28,00X3,00
Art.-no. 046802830
https://eshop.wurth.co.uk/O-ring-me...isibleSearchTerm=046802830&CampaignName=SR001

Batteries:
2x 20700
or:.
2x 21700

Switch, mounted in the rear cap:
https://www.mouser.co.uk/ProductDet...=/ha2pyFadugMMnaI3GbqTadPHnsUUyUYeOrFVdlJb3k=
Mouser No:
999-P5-V52122
Mfr. No: P5-V52122
Uses 3/4-20 threads, Hex Nut included.
Handles up to 5Amperes resistive load according to the datasheet. It locks in either on or off position.

Drawings, blueprints and IGES files:
https://www.dropbox.com/sh/u5leblwxfuqm2ol/AACJAaLgSKooqBJ1pyzgLLh-a?dl=0
( note, threads is missing on the Ø28 mm dimension on the flashlight head, should be M28. Other threads may be used if suitable.)
O-rings and circuit boards, and lens is not included in the blueprints or assembly drawing.

The flashlight measures 279mm aka 29.7cm, that's 10.98 inches total length.

Created with:
https://www.freecadweb.org

 

[RetroTechie]

O-ring inner diameter = outer diameter of glass / reflector. Read: O-ring would go around those.

I think you want O-ring to sit between lens & flashlight body somehow? In that case you'd want the outer diameters to match. Also at that position I'd go for a flat rubber ring rather than one with a circular cross-section. 3 mm thickness is rather much on top of the lens.

 

[Erilaz]

O-ring inner diameter = outer diameter of glass / reflector. Read: O-ring would go around those.

I think you want O-ring to sit between lens & flashlight body somehow? In that case you'd want the outer diameters to match. Also at that position I'd go for a flat rubber ring rather than one with a circular cross-section. 3 mm thickness is rather much on top of the lens.

The threaded part of the lens holder has a inner diameter of 39mm, outer diameter 48mm.

So using a 39mm inner diameter and 48mm outer diameter, 2mm thick rubber gasket will be OK?

Würth does not have O-rings with 39mm
inner diameter.
The O-rings will be compressed by 0.7mm during assembly. I think that it should be enough to make the flashlight waterproof.

I have no mechanical education, so I hope I don't have done other "ooops'es".

English is not my main language.

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