P60 module dimensions?

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wquiles

wquiles

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I am trying to do a project using the now universal P60 module, but although I can find lots of P60 modules and hosts, I have not been able to find a site/link that has the actual dimensions for the P60 module, with enough information to actually make one in a lathe/mill/etc..

I have searched and found good "generic" information so far:
P60 drop ins

P60 hosts

P60 Wiki


The best information I have been able to find so far is this:
Bezel diameter: 26.5mm
Copper base diameter: 19mm
Height including support spring: 36.7mm
Height excluding support spring: 28.8mm

But as a machinist would tell you, that is not enough to make one, specially details such as the angle on the reflector (that matches the P60 host), etc. :D

I have a couple of P60 modules, but before I measure/reverse engineer them, I figured I would first try to find actual drawings - can anyone please help?

Will
 
IMO the easiest approach is to measure the ID at the very front on the tube & measure the ID at the bottom of the tapered socket, then measure the distance between top & bottom & you'll have the info needed to calculate the angle. I imagine you have a few 6P bodies (or clones) laying around :)
 
I have Malkoff, Oveready triple, and VanIsle quad modules, as well as Solaroforce, FM, and Surefire hosts. I have a nice set of digital calipers that I use for reloading also. I know this is not much help, but just LMK if you want any measurements off of any of this stuff...
 
I got a couple of P60 modules and hosts, and I can make my own measurements as well, but I wanted to first try to find the documentation on these - kind of hard to believe that we have a "standard" module/host but no detailed documentation on it :crazy:
 
I thought the p60 was a surefire design, and that all of the derivations were based on measurements of random samples. If true, only Surefire can tell you what their tolerances are.

It gets interesting when you start trying to make a part that will fit in a host that was built to use a copy of a drop-in whose dimensions were copied from someone else's design to fit someone else's host.

I recall a few years back when a batch of 'e' tailcaps from McGizmo were found to work on only some lights. It was unclear which was out of spec, the light or the tailcaps.

Daniel
 
Regarding host dimensions, I put these together a couple of years ago from measuring up a few of my SF's, the measurements were pretty consistent across my modern C-series hosts. I imagine my older Z's might be a bit different, but that's about it.

SF6Pbody_headend.jpg


SFhead_bezel-1.jpg

The variations were pretty tight from host to host, from what I could measure; ~ +-0.002" max from my spot checks, IIRC. Again, I only checked a few of their more modern hosts.

BTW D1 in sketch #1 and D1 & D2 in the second were pretty difficult to get, but after some effort I was pretty confident with them to within ~0.001" or so.

I also did a full set of measurements on the SolarForce version - many of the internal dimensions were notably different.
 
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Elzetta designed their lights specifically to house the Malkoff module & my guess is that those run toward the minimum dimension for better heat transfer. It would be interesting to see how those compare with SF.
 
precisionworks said:
Elzetta designed their lights specifically to house the Malkoff module & my guess is that those run toward the minimum dimension for better heat transfer. It would be interesting to see how those compare with SF.
Click to expand...

I have a Malkoff module on order, but from what I can tell in pictures, Malkoff decided to forgo matching the "angle", and have the module rest on the lip of the outer body/edge, and then make the fit between the dia of the module and the ID of the body as good as possible to improve heat transfer, which is different than most/all other modules that depend on the angle on the reflector to achieve contact/alignment with the body - that to me makes a lot more sense, and basically eliminate minute differences in the angle from host to host, therefore making for a better thermal transfer among many/various hosts. Very clever ;)
 
OK guys, I "officially" request that you please take measurements of your host and P60 modules, to "compare notes" :devil:

As I expected, things are all over the place :D

Here are my own quick measurements today - pardon the hand-drawn, crude diagrams.

The 3x hosts and 2x modules to check out:
DSCF7215.JPG



And my quick measurements on the 2x modules:
DSCF7216.JPG


DSCF7217.JPG


DSCF7218.JPG



Then measuring the "middle" ID of each host:
DSCF7219.JPG


DSCF7220.JPG



So, what do your P60 modules and hosts measure?

Will
 
I am not asking for super-duper details - just the outside diameters at various points in the P60 modules would be very helpful, as well as the single ID on the hosts (any/all hosts, but specially the SF hosts) :D

Will
 
Every manufacturer who copied SureFire started by measuring SF's dimensions (both inside the head & outside the P60 lamp assembly). Measuring every host made will yield a confusing assortment of dimensions because some manufacturers use sharp tooling, newer machine tools, have QC checks, and stay close to target dimensions. Other makers don't have the tooling or machine tools or QC checks & they will tend to run big ... or small ... or right in the middle ...

You'll spend a lot less time if you use Plan A & pick one drop in like the Malkoff and design the host around those dimensions - that's exactly what Elzetta did to get a size-on-size fit. Plan B is to find the largest drop in made & design around those dimensions. Plan C involves finding the smallest host.

Plan A is certainly the most cost effective.
 
precisionworks said:
Every manufacturer who copied SureFire started by measuring SF's dimensions (both inside the head & outside the P60 lamp assembly). Measuring every host made will yield a confusing assortment of dimensions because some manufacturers use sharp tooling, newer machine tools, have QC checks, and stay close to target dimensions. Other makers don't have the tooling or machine tools or QC checks & they will tend to run big ... or small ... or right in the middle ...

You'll spend a lot less time if you use Plan A & pick one drop in like the Malkoff and design the host around those dimensions - that's exactly what Elzetta did to get a size-on-size fit. Plan B is to find the largest drop in made & design around those dimensions. Plan C involves finding the smallest host.

Plan A is certainly the most cost effective.
Click to expand...

I suspect that will be the case, but I am not talking about buying all of those hosts/pills, nor measuring every host/pill combo ever made (I agree it is not worth it). I just want to learn about the stuff "we" the members here in the forum have. I "still" would like to know the ID of the SureFire hosts (you particularly handle a LOT of these lately), and other drop-in modules (including the popular Oveready), to know the aproximate "range" :D

Will
 
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I measured what I have on me right now, a G2 that I keep in the car wth a Titanium Innovations D1000 by NeoFab.

The D1000 has a brass body like a Malkoff, but has a longer taper from the front rim diameter to the main body diameter: All H dimensions taken from the front as a datum.
Length of brass body=29.00mm without contact spring; Bezel rim diam= 26.45-26.50mm; Rim extends 2.7mm from the front then tapers down by H=5.1mm from front (tapers between H= 2.7 and 5.1mm). Main body is 22.04-22.06mm diam(22.17 with an adhesive label that covers 45% of circumference); The ~22.05mm diam body extends to H=17.35mm from front before tapering down to 18.45-18.46Diam at 25.5mm from front. It is 18.45-18.46 from H=25.5 to the end at 29mm total length. The contact spring is ~6mm long.

For the G2 I measured the same dimensions as the sketches in Post#6: Top sketch: D3=24.35-24.42mm; H2=8.85mm(0.349"); can't reach D1 with my calipers. The G2 has an intermediate bore of 22.48-22.4mm(~0.886") between the shallow D3 and your D1. H1a=22.5-22.65mmBottom Sketch: D1=23.92mm(0.942mm); No D2 dimension as there is no step there; D3=28.87mm(1.137"); H4=26.83mm(1.057"); No H2; H3=33.45-33.62mm(1.317")

Note: Parting lines from plastic molding add some variation to the G2 Height dimensions.​
 
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