New triple XPG / single XPE light build

[brad72]

Well I got the itch to make another light. After getting the Triple cree XPG and finding that the optics give a wider beam than expected, plus the 1C tint being a bit cold to gice a good contrast out on the bush trails I decided to add a WH tint XPE with a Ledil LXP spot lens to add some warmth to the light and also some throw.

I knocked up the housing tonight and it looks like it should work but may be a bit fiddly to machine on my manual mill. It's about 40mm(H) x 65mm(W) x 55mm(L). The leds are driven by a 1000mA buckpuck since i had one in stock but the rear cutout area can easily fit a bflex or the like. I have added some silicone 'O' rings to the front at rear covers plus a 2mm polycarbonate front lens to protect the optics. The cooling fins have an area of 8000mm² which may or may not be enough but there is plenty of extra area I can machine if required. I kept the hood over the leds as it works so well on my last build. Weight wise is looks like it will be around 150g. Bit more than I would of liked so might need to shave some of the bulk down

Here are a couple of CAD rendering of the prototype.

Now I just need to find some time to machine her up

 

[PCC]

That looks really nice. I like the mirror finish on the bottom side of the hood, too.

 

[Lampyris noctiluca]

Lovely CAD renderings and good looking design, i could really do with a hood on my light to protect my eyes on those steep, out of the saddle climbs

If you want more throw from an xpg try a ledil regina reflector... amazing reults from such a small reflector

 

[brad72]

Thanks for that. The hood does do a great job of stopping me getting blinded by light when out of the saddle. Will have to build the next light with some Regina optics

 

[brad72]

Start machining today. The parts arrive from cutter on Monday. I ended up using the Bflex driver in the end as the light will be far better with a remote momentary selector switch and let battery low voltage warning.

Also after tweaking the housing the weight should be about 120g. Starting to get a bit excited now. MY wife just give me that so what look when i start rambling.

Makes me wish i had a cnc but the lathe, mill, rotary table, DRO and 2 arms does a pretty good job. Housing taking shape shown below

 

[brad72]

Got the light finished and have been using it on my mtb this winter and it has proved to be a great light. Machining the housing with a manual mill was fiddly and took about a day to complete, but fun none the less. My next light will be round and made on the lathe and should take a fraction of the time machining the housing.

I ended up using the bFlex in the end with a remote switch , using the shell of a single led flasher housing, installing a monetary switch and led to indicate battery low voltage. I've been running it with a 22.2v pack as thats all I had but an 18.5v would have been better, smaller and lighter.

The combination of xpe and xpg has been good with the mix of tints giving a nice colour temperature when out in the bush. I ended up using Cree Triple XPG R5 1C tint with 20mm frosted medium or clear narrow optic and a Single XPE R3 WH tint with Ledil LXP narrow optic. The light output is pretty good and having the 3 power modes on the bflex is great, but just low and high would of been fine.

Heat wise I had no problems in winter and with summer coming it will interesting to see how this housing handles 1A setting on long rides.

Here are some picture of the build

This shot is the triple xpg frosted meduim & single xpe frosted spot @1000mA. The tree is at 25 meters

This shot is triple xpg clear spot & single xpe frosted narrow @ 1000mA

 

[Crowmark]

I am currently genuflectin' an' grovellin' on my unworthy knees before your mighty talent sir!! :bow:

Seriously, that looks good enough to be a proprietary product, you are to be congratulated.
And yes, I can imagine milling those heatsink fins without the aid of a CNC machine tool would be a really boring PITA!