How to power Osram 64623 in a D body?

[reptiles]

Greetings, I'm thinking of my first major hotwire light.

I already ordered the fine looking 3" aluminum head (mates to a D size Mag) that Delghi is making. Includes the glass lens.

I requested a bulb opening of 0.472 in the Carley relector so I can use an Osram 64623 (or similiar bulb.)

While I'm waiting for that to arrive, I thought I should get moving on what else I need to acquire to complete the light.

I want to make a firestarter type demo -- all light, little run time monster.

I have a bunch of questions that I'm currently looking for answers... if anyone can kindly advise on any of these (and provide part sources) it would be most appreciated:

If I use the above bulb, I think I need about 15-16 volts. So what is the best way to assemble rechargeable NiMH cells in a D cell (2, 3 or 4 cell? length) to provide that? Powerpacks? AA battery holders? I'm thinking of direct drive.

Will I need a high temp KIU bipin socket or are potted Osram bulbs available? Where?

Considering the bore size of 0.472" is the Osram 64623 still the best for this application?

The 3" head is natural hard III anodized... any chance someone has Mag bodies available in natural hard III? Still not sure what length I need.

Also will a stock Mag switch take the high amps? Anyone make a better one?

What else I have over looked? What surprizes have I in store? lol

Many thanks!

Regards,

Mark

 

[JimmyM]

What you're trying to build is called a Mag623.
You need a tri-bored 3D body to accept 2/3A cells like the Elite1500s. You'll need 12 to 13 cells. 12 cells will fit in a 3 wide by 4 long pack in a tri-bored 2D but you'll need to go to a 3D to fit in one extra cell and 2 dummies in a 3 wide by 5 long pack.
I haven't tried it but you might be able to use a 3 wide by 4 long in a tri-bored 2D body with a 13th cell mounted axially at the very end of the pack. Of course you'll have to modify the spring.
The switch will survive quite well if it's fully modified.
Search for Mag623 or M@g623 or M*g623. There are even a few for sale.

 

[reptiles]

Thanks for the info... very useful!

Regards,

Mark

 

[LEDcandle]

If the Li-on D cells came thru, you can get your 12v or 16v easily (3D or 4D mag)...
But apparently there is a delay. There should be some D Li-ons floating ard too because Emilion made a batch.

At 5200 mah, a hotwire of your sort would run it at 2C which I believe is pretty safe territory. But of course, NiMh's are safer.

The stock switch will work, but it might 'stick'. My 150w mag draws about 7A from the batts, using stock switch. Not sure how it looks like inside now, but it works. But it'll cause resistance and it will get stuck sometimes and needs some coaxing to switch off.

Maybe over a prolonged time, the switch will fail. Or maybe not.

 

[roadie]

join me !!! welcome !!! i scorced my bill jus now ....

 

[Nereus]

I suggest that you use a low on-resistance mosfet instead of the standard switch. Leave the original switch as it is and use it for driving the mosfet gate. Like this you get rid of voltage losses across the switch.

-N

 

[goosefraba]

I was planning the same, but where to get all the required accessories. The kiu hi temp sockets are all gone (except for D cell), Lens. I, We need help!

 

[reptiles]

I suggest that you use a low on-resistance mosfet instead of the standard switch. Leave the original switch as it is and use it for driving the mosfet gate. Like this you get rid of voltage losses across the switch.

-N

That sounds very interesting. Can you be more specific? Part number perhaps?

Cheers,

Mark

 

[Nereus]

That sounds very interesting. Can you be more specific? Part number perhaps?

Cheers,

Mark

There are dozens of mosfets from different manufacturers that should suit your needs. IRF1704 is one example - actually it is quite an overkill if you have a look on the specs. Here is the datasheet: http://www.datasheetcatalog.com/datasheets_pdf/I/R/F/1/IRF1704.shtml
The on-state resistance is only 0,004 ohms which means that if your bulb pulls 10 amps the mosfet creates only 0,04 volt voltage loss. Furthermore, IRF1704 can tolerate very well the heat generated by the osram bulb.

-N

 

[LumenHound]

This is a good read.
Maglite Switch Modified for High Performance Bulbs