Need to build a super bright 'pin spot':ideas?

[blasterman]

I have a bunch of aging projector DJ lights that I'm dying to replace because I'm tired of replacing 50 hour 250-watt bulbs. Plus, the fixtures aren't all that efficient in the first place, so I figured 2000 source lumens of LED would easily do a better job. Since it's a fixed light, powering and heat-sinking is already solved. Optics and LED choice however is a bit frustrating. I need no bigger than 5-degree beam spread, and tighter is better. I can use a couple high powered LEDs like Bridgelux or multiple smaller ones. Those options are open. Using hyper expensive optics is not an option.

I've been using Best Hong Kong Prolights and their 10degree reflectors for similiar projects because I've found the beam angles tighter than any Cree + inexpensive acrylic optic. But, for this project I need tighter beam angles.

I got a couple of these inexpensive flashlights from DealExtreme last year, and after modding them with R2s found the beam/throw was absurdly tight. Reflector would be perfect - if I could find them as individual parts I'd just cluser about a dozen R2s on a big heatsink, run them at an amp, and I'd have my beam. The reflector is only slightly different than the cheap ones I get from BestHongKong, but it's obviously designed for Cree.

I'm also open to using Rebels or K2s, but again I simply haven't found much difference in acrylic optics and they all seem to produce the same size fuzzy square as R2s with the narrowest Carlco {sigh}.

Another possible option would be use a really big Bridgelux, and use a big +100mm Condensor from Surplus Shed, but not sure if that would yield the beam angle.

 

[TooManyGizmos]

.
Fiber optic tube ?

or acrylic tube ?

.

 

[bshanahan14rulz]

cree and the DX smooth reflector that comes with the smooth p60 kit at dx has a decent spot, but that probably wouldn't be cost-effective...

 

[blasterman]

Yeah...that's the problem.

Many of the generic >$10.00 flashlights have very tight reflectors (with no front optic), but I can't find where they get the reflectors.

Obviously the flashligh manufacturers aint making the optics themselves, so there has to be a source of cheap reflectors because many of the cheaper lights are using the same ones.