My latest light
- Thread starter snowdawg
- Start date
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Zero_Enigma
Enlightened
Construction details, cost, and parts list please!! 
:welcome::grouphug::goodjob:
:welcome::grouphug::goodjob:
HEY HEY ITS HENDO
Enlightened
looks neat ....
.. what was it in its previous life?
link to mtbr forum??
.. what was it in its previous life?
link to mtbr forum??
nightrider
Enlightened
It does look nice... my biggest concern would be lack of exposed heatsink area, and having the heatsink fins on the back is not the greatest cooling scenario for a bike light. The case is plastic?
But then again, if you ride where it's cold enough to snow, cooling might not be much of an issue
But then again, if you ride where it's cold enough to snow, cooling might not be much of an issue
Thanks for the all the praise.
I finally got my LEDs today so now I can finish this light.
Here are Some Construction details;
The aluminum heat-sink was cut from some scrap that I had. It is basically 1.25" X .75" X 3+" bar.
The end caps are cut from ½" PVC sheet stock.
The front cover and back cover is 1/8" polycarbonate. I bent them with a home made Heat wire jig.
Optics are L2 Optx from LED Supply http://www.ledsupply.com/optx.php $2.25 Each
Buckpuck is from LED Supply http://www.ledsupply.com/optx.php $14.00
Switch is from Digikey.com $1.25
Cree Q5s are from DealsExteam. $9.00 each no shipping cost, but patients is a must.
I machined the parts on a crappy Mini Mill, but it could be done with a Table Saw and a drill press.
I finally got my LEDs today so now I can finish this light.
Here are Some Construction details;
The aluminum heat-sink was cut from some scrap that I had. It is basically 1.25" X .75" X 3+" bar.
The end caps are cut from ½" PVC sheet stock.
The front cover and back cover is 1/8" polycarbonate. I bent them with a home made Heat wire jig.
Optics are L2 Optx from LED Supply http://www.ledsupply.com/optx.php $2.25 Each
Buckpuck is from LED Supply http://www.ledsupply.com/optx.php $14.00
Switch is from Digikey.com $1.25
Cree Q5s are from DealsExteam. $9.00 each no shipping cost, but patients is a must.
I machined the parts on a crappy Mini Mill, but it could be done with a Table Saw and a drill press.
I forgot to add the pic of the back cover that I put on to protect my knees or anything eles that might hit the edge of the heatsink. Here it is in the clear, I back sprayed the cover and all the plastic parts with black "plastic specific" paint for the final product.
Changchung
Flashlight Enthusiast
Amazing job... But, why the yellow plexiglass...???
It is just yellow tape to protect the polycarbonate during the fabrication process.
Changchung
Flashlight Enthusiast
Ok...:twothumbs
I finally got to take my new light on it maiden voyage and wow!!! What a difference over my halogen. I tried to get some beam shots in the woods but they just didn't come out right, so I took some up against the wall. The lights are 14 ft from the wall and it really shows the difference.
I painted the top inside of the lens cover with black paint and the used a reflective tape over that. With the bottom part clear, the spill around my bike is perfect.
Triple Cree
NR H.I.D.
The Cree's and the HID, notice the hot spot from the HID
The overvolted 20W Halogen.
I painted the top inside of the lens cover with black paint and the used a reflective tape over that. With the bottom part clear, the spill around my bike is perfect.
Triple Cree
NR H.I.D.
The Cree's and the HID, notice the hot spot from the HID
The overvolted 20W Halogen.
HEY HEY ITS HENDO
Enlightened
the crees and the HID would make for a killer combo
but on thier own i prefer your cree wall of light which must be pretty amazing in the woods
Nice job! .....especially this bit .....
"The front cover and back cover is 1/8" polycarbonate. I bent them with a home made Heat wire jig"
but on thier own i prefer your cree wall of light which must be pretty amazing in the woods
Nice job! .....especially this bit .....
"The front cover and back cover is 1/8" polycarbonate. I bent them with a home made Heat wire jig"
Thanks... the crees in the woods are awesome. The HID adds a little extra but I could almost ride with the Crees solo. It would be nice to have a triple on my head, but they don't throw far enough and have a too wide of a spread. Maybe my next project.
I gathered some heat data yesterday. I measured the temperate at the back of the heat-sink between the fins. The light was on for about 10 minutes with no air movement. The ambient temp was 38 deg F and the light was 61 deg F. (my buddies mag light mod was 86 deg F measured on the case near where the internal heat-sink is in contact with the outside). I measured the light indoors at 70 deg F and the light was 94 deg F. The temps at the ends of the fins were 8 to 9 deg cooler. As a note of interest, I am measuring the temperature at 3/8 of an inch away, directly in back of the Cree stars and they are drawing about 1A.
I know it is nearly impossible to compare data with other designs, But I would say the heat-sink is working quite efficiently.
I know it is nearly impossible to compare data with other designs, But I would say the heat-sink is working quite efficiently.
dom
Enlightened
Nice job Snowdawg
I was wondering how you machined square corners on the flange of the endcaps but i see you have stuck on some small square bits. LOL
The heat sinking is fantastic if it is only getting to 34C after 10mins.
How heavy is the unit do you know?
Cheers
Dom
I was wondering how you machined square corners on the flange of the endcaps but i see you have stuck on some small square bits. LOL
The heat sinking is fantastic if it is only getting to 34C after 10mins.
How heavy is the unit do you know?
Cheers
Dom
