Surefire XM-L Tower Module DD

maxspeeds

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Justincase and Tx101, do you recall what color bin your xmls are? Do they happen to be the 5000k XML cssish is selling? Also, other thuan the shoppe, where can I find or make a copper shim? namely, the 0.042" thick copper shim?
 

Justin Case

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I bought bare XM-Ls from Digikey and reflowed them onto datiLED's boards. Neutral tint -- 4A, 4B, 4C, or 4D (no choice, that's the chromaticity range that the XM-L kit spans).

You can punch out shims from copper sheet available from onlinemetals.com.
 

maxspeeds

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Thanks for the bins and the link to online metals. Do I need a special tool to punch the circles out of the sheet?
 

Justin Case

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One way is to use a sheet metal "power punch" (search Amazon.com for power punch). The 9/32" punch will give you a ~7mm shim.

The shim will have a dimple in it, which needs to be flattened/removed. The dimple comes from the sharp point on the punch. The punched-out shim often also fits very tightly in the die and can be a slight hassle to get out.

If you don't mind a bit of extra work, you could try punching a copper penny (pre-1982 IIRC) and filing it down to the desired thickness (stock thickness is about 0.06"). Hopefully, the two faces will be smooth, flat, and parallel. Or punch a dime, which is about 0.05" thick.
 

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