Well, it was a Dorcy.

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gadget_lover

Flashaholic
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Oct 7, 2003
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This light is the first one that I've made more or less from scratch. I call him 'Slim. It was supposed to replace the modified Dorcy 1AA that I EDC. The modified Dorcy uses a cell pulled from a CRV3, so it's nice and bright but not always practical. Slim uses a CR123A and puts out about 22 lumens.

I had two objectives. Making it thinner than the stock Dorcy (it's got a huge head and thick body) and make it work off a CR123A. This was actually a mule for practicing techniques. A little turning, boring, threading, knurling and finishing went into it. It's made from 6061 aluminium. It gave me some good practice in making parts to fit other devices.

Slim and his grandfather.
slim4.jpg


I made one piece at a time, starting with a Dorcy 1AA and replacing each piece as it was completed. I kept the electronics from the Dorcy including the spring contact. The head fits on a stock 1AA or 2AA light and works! The body fits into a stock 1AA 3 led head. The tailcaps are not stock.

The tailcap on the left is a 'tactical twistie'. It has a pushbutton for momentary use. You can tighten it down all the way for constant on. The tailcap on the right is a normal twisty.

The Kroll was added as an afterthought. It required an adapter because the inside threading was .75 mm pitch and just a touch wider than a CR123A. The Kroll requires a 5/8 x 28TPI thread.

The Lux III is thermal epoxy'ed to the heatsink. The luxeon is actually fairly well centered. The optic is an NX05 that I had in my parts kit. I may change it with a Fraen LP. It gets warm after a few minutes of use, but not hot.

It puts out the same beam as my ARC LSH-P, with the same measured brightness. Beamshots would be redundant, as everyone has seen what an ARC beam looks like.


slim2s.jpg



For comparison, some other 1 cell lights;
slim1.jpg



The parts (doesn't look like a Dorcy, huh?)
slim3s.jpg



And the twisty cap
slim5.jpg


The body will eventually be replaced with one that's a little better made. It won't be compatible with the Dorcy, so I'll have a bit more lattitude as far as shape, length of threaded section, etc. I'll probably upgrade it to a badboy at 500ma to get a bit more light. I still want long runtime, so I'll figure out a way to make it two stage too.

Daniel

BTW, I was not going to post about this light, but my wife sort of goaded me into it. I guess she's tired of me coming into the room after each improvement and saying 'See!!!'.
 
Well done Dan! Now get out that knurling tool and risk.../ubbthreads/images/graemlins/icon15.gif

Larry
 
[ QUOTE ]
tvodrd said:
Well done Dan! Now get out that knurling tool and risk.../ubbthreads/images/graemlins/icon15.gif

Larry

[/ QUOTE ]

LOL! That's for the NEXT body. I finally got this one nicely finished in brushed aluminum. I was amazed that the line between the body and the kroll adapter almost became invisible when I did that.

I almost forgot! Thanks for the good words guys.


Daniel
 
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Hi Kritt,

I take that as a BIG compliment. /ubbthreads/images/graemlins/smile.gif

It's really not the kind of thing I would sell. Each part is hand fitted and should work well for a long time. None of it is over stressed. However... Some features like o-rings need to be added. I designed it so that I could swap out the LED+heatsink as desired. The brushed aluminum finish looks nice, but I want to see what it looks like after a few weeks.

But again, thanks for asking.

Daniel
 
I definately like the looks of that... I think something like that (esp the very trim 1x123 form factor), with a 2 stage tail would make a perfect EDC.

Great work.
 
Thanks Guys.

I just happen to have a CR2 sitting on the bench. I was thinking that would make a nice little purse light for my wife.

Part of my original thinking was that I could move the head to a stock 2AA Dorcy or even a 1AA if I ran short of CR123A batteries.

The slim body works pretty well as far as everyday carry goes. I barely notice it in my shirt pocket. Compared to the ARC LSH, It stands out a little less in my pants pocket because of the longer and slimmer shape.

Daniel
 
People like you make me jealous like crazy. I wish I had the know how and more than anything, equipment (and time...), to be able to make things like that.

Great work.

Oh and if you ever need a beta tester... /ubbthreads/images/graemlins/rolleye11.gif

edit: I see I bumped a rather old thread (was linked to it and didn't even think about the date hehe). Oh well, it deserved a bump /ubbthreads/images/graemlins/smile.gif
 
The neat thing about flashlight building is that it does NOT take a million dollars worth of hardware. It does not take years of training either. It does require that you devote a shop to it.

This light was made using only a Harbor Freight 7x10 lathe and a few simple hand tools. The lathe can be had for as little as $300.The lathe is set up on a portable bench in a little nook of my garage.

There are on-line tutorials that will teach you all the basics. That's where I learned what I know.

You don't need a great deal of manual dexterity. I'm all thumbs, and generally donate a drop or two of blood to every project.

5 months ago I'd never touched a lathe. I saw what Unnerv did with his and was envious too. 3 months ago I bought one and made my first part, a plastic disk for a chair leg. Since then I've made a dozen parts for different projects. This is the first light I've made from scratch.

It does take time, especially when you are learning. You can spend hours making large metal sticks into smaller ones surrounded by piles of metal shavings. Lathes also tend to create the need for supporting tools, but you can make many of them with the lathe itself. In fact, you will make many just because you can.

So by all means, put a lathe on your Christmas wish list. It's not only useful, it's also fun and fulfilling too.

As for the light? It's now part of my EDC despite the beating that the brushed surface is taking. I'm starting on 'slim, ver 2.0' to see if I can incorporate all that I learned from creating (and using) this one.

...and thanks for the kind words.

Daniel
 
Dan - nice work. I see that you decided to up the ante on the home made light front. No Fair - I had not even gotten my proto working yet. /ubbthreads/images/graemlins/smile.gif BTW - Thanks for taking the proto pics.
 
Thanks Harry,

Having seen the beautiful work that Unnerv, McGizmo and others do, I can only claim credit for upping the ante on the home made light front in Pleasanton.
/ubbthreads/images/graemlins/smile.gif

We'll see who's ahead after you start putting together your lights.

Daniel
 

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