New here and would like help building an led light

[12ga]

I would first like to say I think a site like this is cool, and thank you fellas for letting me join. I am new to the site and the flashlight culture. I have many questions all of which I am sure will be answered here. I recently watched a video produced by a person that converted a 60-lumen dorcy led flashlight into a 900 lumen led flashlight. In the question section someone from this forum made mention that, help could be sought here on how he went about this process. Please keep in mind my technical knowledge is good but, after reading some post I understand not on the level here. I would just like to know how I could convert a small led flashlight into this 900 lumen monster I believe some of you fellas make on a daily basis? Any help or instructions would be much appreciated. Moreover, thanks again for any help in advance.

 

[12ga]

I will start this thread by telling you gentlemen what I have in mind. I have a small skil 9-led light that I would like to install a p7 into. Through research I have learned a heatsink is very important and the load to the light to create 900 lumens. The light as it sits runs off three AAA batteries. Where can I find things like a heatsink to fit my application? I will need a new reflector going from nine bulbs to one, where would I find something like that? What type of batteries should I use? I just need a little help here to get the ball rolling. Any help would be greatly appreciated.

 

[old4570]

First = Just what host / battery are you going for ..

900 Lumen ???

 

[Gunner12]

By definition, LEDs aren't bulbs. Those 5mm LEDs produce a minute amount of heat when compared to the P7, so going for a heatsink like you were asking is a good idea.

AAAs will have trouble holding the high current that the P7 needs. Also, 900 lumen is the maximum possible output at 2.8 amps for the higher bin P7, so you won't get 900 lumen out the front (after optical losses) unless you overdrive the LED enough.

The reflector will depend on how much space you have left after you add in the thickness of the heatsink, LED, and window (or lens as some choose to call it).

Do you have a link or pictures of the light so we know what you are working with?

:welcome:

 

[12ga]

Here are some photos of the light to which I am referring. It is a simple light, but I am new to the aspect of dealing with the electronics boards. I would like to make this as bright as possible without getting too overwhelmed. The only reason I mention the p7 light is that I understand that that light emitting diode is the brightest one available. If I can go with more than on led or a different kind for my application, please feel free to chime in. Like I said, I am not looking for someone to hold my hand throughout this whole process. I am just looking for someone who can give me a jumpstart and get me on the road
.

 

[12ga]

I must apologize for the poor picture quality the photos were quick snap-shots from my phone. I can add more pictures if needed. The first is the expanded view the second is a view of the light in working order. In addition, I have a quick sketch of how it should look complete in the housing. Forgive my archaic artwork but it serves a purpose.

 

[old4570]

Sweet lord !!!!
:naughty: I know that flashy , I actually bought one myself but at least it was the Luxeon one . Its junk , sorry , but must not lie .


A J-Bin SSC P7 that has higher vF and this driver board

Should run under 2A , and give maybe 30 minutes on high , maybe ?

Buy a better host though ...

 

[12ga]

Just something I had laying around, what would you suggest to start with, now knowing my situation.

 

[Gunner12]

I wonder if a P60 type drop-in can be made to fit...

There are a few LEDs that are brighter then the P7, for example, the SST-90 can hit over 2000 lumen, but even the P7 would probably be limited by heat here, so with the SST-90 you would get a real flash-light. Run in flashes as not to overheat the LED.

The larger outer spring is probably for negative contact.

How big is the LED board? If it's around 20 mm, then you can use the Seoul P7 LED boards from DX as heatsinks. But that still won't be enough heatsinking if you are driving the P7 at anywhere close to max recommended current.

 

[matrixshaman]

Throw away the light you currently have - worst kind of junk to try to mod. You don't want to use 3 x AAA for anything really and especially not a P7 or better. Installing a P7 into any light not made for it will be a lot of work to get right as it involves getting a proper reflector machined and shimmed right and things that modders here may charge a lot for. I've got a P7 in a Novatac type body that ran about $350 with a good driver and a finely tuned beam. As I assume you may not want something that expensive (and these are not readily available anyway) I'd suggest you just look for a flashlight that is already built with a P7. If you want low price look at dealextreme.com but expect slow delivery. If you can spend a bit more look on the marketplace in the dealer section as a lot of dealers there sell P7 based flashlights for fairly good prices. Putting a high power LED like a P7 in a light is a lot different than dropping in a P4 or other medium power LED into a light that supports something in a similar power range. The light you've got there would end up being more trouble than it's worth to try to make it into a decent 900 lumen light. DX has P7 based flashlights starting around $37 and I'm sure you'd spend way more than that trying to convert your current light and it would not likely be as good as one of the cheaper DX lights. On the other hand if you've got a good metal lathe and can turn stuff yourself you might want to tackle building one from scratch. Just don't waste time on the Skil light.

 

[Gunner12]

^ He's got a point ^

It will be cheaper and easier to to buy a new LED light. Don't expect 900 out the front lumen from any P7 light though, with optical losses, even the best bin P7 won't hit 900 lumen out the front unless it is overdriven.

But then, this is CPF...

 

[12ga]

I thank you gentleman for your time. I have posted another thread in the led light area asking which light I should start with, I have filled out a checklist I was told would help me help you guys point me in the right direction.

Thanks again for all of your help,
12ga.

 

[T0RN4D0]

The cheapest way to getting a _good_ P7 flashlight would probably be getting a decent 2x18650 host (don't bother with less if you want 900 lumens). Then you make sure it has good heatsinking and that the heat transfers to the body, and maybe change the driver if its underdriven...