Disclaimer: Use this advice at your own risk.
Here is how I get a very thin film of electrically insulating epoxy under my Seoul emitters. :wave:
First, gather up your copper discs that you have on hand for modding. Might as well do them all at once. First, flatten them between two flat surfaces so that they do not have a dish-shape or burrs.
Typically .015" works (as shown below), but sometimes as much as .030" is required. If you don't plan on using a copper disc, stop reading. :duh2:
Mix up your thermal epoxy as directed. Don't under mix, get those two epoxy components well entwined! Now apply the thinnest possible coating to the top of the disc, just enough that the copper is barely visible entirely across the disc. I use tweezers to hold the disc still while applying the epoxy with a dental pick. You can probably do about a dozen before the epoxy starts setting up and becoming difficult to work with.
Now cut some "plumbers" teflon tape and lay it across several discs in a row. Tap lightly with your finger on the tape to make sure the tape is sticking to the discs. Now turn over the strip on a flat surface (I use a tablet) and press with a slight firmness in the very middle of each disc, until you cause a shimmer of epoxy to show up all around the disc edge.
After 15 minutes you can peel your epoxy-coated disc off of the teflon tape. If copper is showing on some, you can touch them up and repeat, or remove all the epoxy, clean with isopropyl alchohol and start over on those.
Now whenever you want to place a seoul emitter, you can confidently epoxy the disc to the pill (make sure it is burr-free) knowing you will get great electrical isolation and the best thermal transfer possible from the copper disc to the pill. Epoxy the disc down, already coated side down, squeezing most of the fresh epoxy you applied during installation, since you alread have an adequate film. Check it with an ohmmeter, of course, before installing the emitter. :huh:
The emitter can be installed directly onto the copper disc with thermal epoxy or compound as you choose. :thumbsup: Just give it time to completely cure before you use the light, a few hours would be best.
P.S. Don't press on the top of the emitter dome - EVER. Don't install the reflector so that it presses on the top of the emitter plastic. Give the emitter some clearance. Hard pressure on the emitter can cause a bridge across the epoxy!
Here is how I get a very thin film of electrically insulating epoxy under my Seoul emitters. :wave:
First, gather up your copper discs that you have on hand for modding. Might as well do them all at once. First, flatten them between two flat surfaces so that they do not have a dish-shape or burrs.
Typically .015" works (as shown below), but sometimes as much as .030" is required. If you don't plan on using a copper disc, stop reading. :duh2:
Mix up your thermal epoxy as directed. Don't under mix, get those two epoxy components well entwined! Now apply the thinnest possible coating to the top of the disc, just enough that the copper is barely visible entirely across the disc. I use tweezers to hold the disc still while applying the epoxy with a dental pick. You can probably do about a dozen before the epoxy starts setting up and becoming difficult to work with.
Now cut some "plumbers" teflon tape and lay it across several discs in a row. Tap lightly with your finger on the tape to make sure the tape is sticking to the discs. Now turn over the strip on a flat surface (I use a tablet) and press with a slight firmness in the very middle of each disc, until you cause a shimmer of epoxy to show up all around the disc edge.
After 15 minutes you can peel your epoxy-coated disc off of the teflon tape. If copper is showing on some, you can touch them up and repeat, or remove all the epoxy, clean with isopropyl alchohol and start over on those.
Now whenever you want to place a seoul emitter, you can confidently epoxy the disc to the pill (make sure it is burr-free) knowing you will get great electrical isolation and the best thermal transfer possible from the copper disc to the pill. Epoxy the disc down, already coated side down, squeezing most of the fresh epoxy you applied during installation, since you alread have an adequate film. Check it with an ohmmeter, of course, before installing the emitter. :huh:
The emitter can be installed directly onto the copper disc with thermal epoxy or compound as you choose. :thumbsup: Just give it time to completely cure before you use the light, a few hours would be best.
P.S. Don't press on the top of the emitter dome - EVER. Don't install the reflector so that it presses on the top of the emitter plastic. Give the emitter some clearance. Hard pressure on the emitter can cause a bridge across the epoxy!
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