Malkoff look-alike P60 module (TIR optic in a case)

[kosPap]

Well this one steals the Idea of the Malkoff M60...
Putting the optic in a case that also contacts the flashlight body for heat dissipation...

Materials

A DX/KD optic, a P60 module, and a sacrificial reflector.

Tools

This was made strictly with handtools...a saw blade, a round/flat file, a grinding stone, a paper cutter and sharp sniping pliers....But a lathe will make the work VERY fast, easy and Clean

Working on the optic holder

First we clip of that thick band on the rim.
BUT...we do not want to maintain the holder's cone angle on the area we remove the material...if we do we will thin down a critical area (shown at point D) and the holder will separate in two. So we got to leave just a bit more material
We should just change the angle a bit (as shown at point C) and remove half of that thick bands width.

You may have noticed that I have clipped off the optic holders "feet" that surround the Cree base...Since I want interchangeability between pills and keeping the isolator disc I am using only the holder round socket to position it on the LED.
It also allows the reflector/optic group to screw down ON the LED

Forming the reflector...

A new hole was drilled at the bottom to accept the optic and its edges were chamfered a bit... the optic must sit flat and flush....

Then more attention was given at the reflector opening...First thing is to cut the horizontal band off (area A below).

Take not that you should not go straight for the junction of the band and cone part of the reflector. You got to leave something to polish off and have the reflector sit flat with the flashlight body.
This is critical 'cos if the module moves forward there will be no contact with its socket. ALSO removing material from the cone will decrease the reflector diameter.

This mod was made on a Solarforce L2M 2009 body...Modules sit differently in different flashlights so I suggested you install the bare reflector, mark the rim position, THEN cut.

Now we are working on the reflector interior. First we got to chamfer the new edge...how much the optic will tell us...But we have to also remove material from a band beneath the rim (see area B)....we need that extra space for the optic.

For this point on it is try and grind off, try and grind off.....Then end comes with epoxing the holder in the reflector...

Well here it is...2 hours of hand work for the benefits of the optic....

Enjoy, Kostas

 

[pmoore]

You know we are all just sitting around waiting for the beam shots :tired:

Looks good, What driver are you using?

Paul

 

[kosPap]

Beamshots? that depends on the optic. the idea is a method to add an optic to a P60 module...It has nothing to do with performance.
You can take your pick...The one i use is a 10deg one? very E2DL style...You just need good placement for good focusing...

you can use any driver...this is the reason I did not include a pill in the pic....you can screw the module at any Cree XR-E module...

 

[pmoore]

Well, were you happy with the results you have gotten with this one?

 

[kosPap]

yep..a bit...this optic was not great...but It was bought in a set of 5 from DX and it was sacrificial...infact I totally messed up the first one so I made another...

the 8 and 45 deg ones from DX/KD are formidable!

 

[Owen]

Re: Making a Malkoff look-alike P60 module

I love that you've basically made a Malkoff where you can choose your optic, and interchange pills in for different battery setups or upgrades.
Will that fit, or could it be made to fit, in a VME bezel, and work with a E series body? Cool mod, either way:thumbsup:

 

[vomsaver14]

You may have noticed that I have clipped off the optic holders "feet" that surround the Cree base...Since I want interchangeability between pills and keeping the isolator disc I am using only the holder round socket to position it on the LED. It also allows the reflector/optic group to screw down ON the LED

 

[saltytri]

FWIW, if you're going to go to the trouble of doing this mod, the genuine Cree optic that Malkoff uses is vastly better than the DX/KD knockoffs. I've compared all three side by side and the Cree has a much nicer beam. At only $2 each, they're a steal: http://ledsupply.com/247-10-lens.php

And they arrive from LED Supply in a few days instead of sometime between a few weeks and never.

Last but not least, this is a very clever mod that most anyone can do with simple tools and it ought to give a rewarding result. Nice work!! :thumbsup:

 

[Sgt. LED]

You put a lot of work into it. Cool

 

[kosPap]

thanks guys for your comments...

Owen...I cannot know on the VME...If I had one I would...but the mod is effectively a shortened P60 module with the band cutoff...can someone try?

saltytri
Indeed it could not be otherwise...but it is a killer buying small value items from US when you are overseas..ie I had to wait sometime to build up an order from Cutter

Sgt. LED
with my mods going a bit astray If I could I would buy a tabletop mill/lathe..But there are more pressing money eaters than flashlights

Update and Considerations:

This has not actually has to do with the mod itself. but with the fit od the P60 modules....While checking fit again I noticed taht using a thick strong outer spring the reflector/case would not go all the way down....
Now the L2M2009 socket is cylidrical and that means that there was not a proper metal contact to transfer heat. Only what may come from the spring itself.

That reconfirmed my observations at an ealier date...

(paint scracthes off in REAL contact areas)

So....despite the fun of it nothing can beat the real thing (malkoff) in a real thing (Surefire)

 

[saltytri]

saltytri
Indeed it could not be otherwise...but it is a killer buying small value items from US when you are overseas..ie I had to wait sometime to build up an order from Cutter

kosPap: I'm feeling a little sheepish that I didn't notice your location. I do understand that supply issues might make you put some thought into doing the best you can with parts that are reasonably available! So, let me back up and say that for those who have easy access to the Cree parts, they are great. If you don't, enjoy what you've got!

 

[kosPap]

indeed, indeed...

 

[orbital]

+

Way to go kostas, ..gotta dig stuff like this!

 

[Owen]

Owen...I cannot know on the VME...If I had one I would...but the mod is effectively a shortened P60 module with the band cutoff...can someone try?

Ah. I wasn't paying enough attention, and forgot that people have used P60 dropins in the VME bezel. Because the mod is shorter, it may not fit as is without having to back the pill out too much(depending where you have to set it to focus with the optic), but it might work just fine if you put a lens in there, too.
Plus there's the idea of just shortening the reflector without even using an optic, and adding a lens, allowing us to use stuff like the multilevel Dereelight and other dropins with the VME without any kind of length or focus issues.
hahahaha, you just cost me some money. Thanks

 

[kosPap]

hahahah! I like it....

Anyone care to try it on a lathe?
Neailbender how about some?

 

[saltytri]

If you have a lathe, you might not want to trash a perfectly good reflector. Instead, you could make one of these out of a bit of scrap aluminum:

 

[kosPap]

yeh baby!

:bow::goodjob:

 

[kosPap]

If you have a lathe, you might not want to trash a perfectly good reflector. Instead, you could make one of these out of a bit of scrap aluminum:

Ok in a more serious mood....if you plan tomakin some for sale drop a word, will you?

 

[saltytri]

Kostas:

The problem is that each sleeve needs to be made to fit a particular pill because the threads vary enough from pill to pill that one sleeve does not fit all. So, it's custom work and not at all practical unless working with pills sourced from one supplier at one time.

 

[kosPap]

I see..thanks

(though if you had a derrelight pill I would buy an Optic case)