Ultimate Maglite D heatsink

Erasmus · Jun 15, 2008

Hi there!

I'm trying to make a Mag 2D running 7 Cree XR-E R2's on 8 NiMH AA's with a MaxFlex2 driver. All parts are available, but I can not find a good heatsink. So I designed a new custom heatsink

This heatsink is made for ultimate heat dissipation from the LEDs to the flashlight head and body. It also offers enough space for no less than 7 McR-16-XR reflectors, however the reflectors need a tiny bit of dremel'ing.

Here is the design :

Here are 2 alternative designs, which is actually just a part of the above heatsink.
http://i277.photobucket.com/albums/kk61/Pallieter85/Mag D heatsink/MagDsinkalt.jpg

Feel free to discuss the design and possible improvements, I'd like to get some feedback

Thanks!
Erasmus

wquiles · Jun 15, 2008

In my opinion, not too difficult to do if you have a lathe - looks like a nice 2-3 hour project to do in a weekend, specially if the 25mm x 34mm piece at the bottom is solid - this would mean that you can cut the whole thing without ever removing from the chuck (all operations from one side)

I prefer the single piece design, but that is just me

By the way, great job with the drawings - which package you used?

Will

LukeA · Jun 15, 2008

wquiles said:
By the way, great job with the drawings - which package you used?

Will

SketchUp? Based on this and the copper bases for Crees.

Oh, and in the first one and last one, the max OD for the part contacting the inside of the head can be as large as 48.2mm. Just something to think about.

Erasmus · Jun 15, 2008

wquiles said:
In my opinion, not too difficult to do if you have a lathe - looks like a nice 2-3 hour project to do in a weekend, specially if the 25mm x 34mm piece at the bottom is solid - this would mean that you can cut the whole thing without ever removing from the chuck (all operations from one side)

I prefer the single piece design, but that is just me

By the way, great job with the drawings - which package you used?

Will

Thanks for the nice comments. The bottom is solid indeed, I'll dril one hole for the wires myself.

For the drawings I used Google SketchUp, probably the most easy 3D drawing software available

Since I am new to CNC, is there some software in which you can design things so you just have to drag these files in the CNC computer so it will automatically make the design? That would be cool

Erasmus · Jun 15, 2008

LukeA said:
SketchUp? Based on this and the copper bases for Crees.

Oh, and in the first one and last one, the max OD for the part contacting the inside of the head can be as large as 48.2mm. Just something to think about.

Yep it's SketchUp

Thanks for the corrected measurements. I carefully measured the flashlight again and indeed 48.2mm is possible for the head and for the barrel 34.2mm is also better. I updated the drawing

LukeA · Jun 15, 2008

Erasmus said:
Thanks for the nice comments. The bottom is solid indeed, I'll dril one hole for the wires myself.

For the drawings I used Google SketchUp, probably the most easy 3D drawing software available

Since I am new to CNC, is there some software in which you can design things so you just have to drag these files in the CNC computer so it will automatically make the design? That would be cool

I have experience CNC cutting parts drawn in Autodesk Inventor. The process is identical for SolidWorks. Using those programs, as you design parts, which you do using a technique called constructive solid geometry, you impart data into the model that allows the model file to be processed by CNC software into g-codes for the machine. SketchUp doesn't do this. To cut these parts out of metal with a CNC machine, they would have to be redrawn in a program that can export a filetype that the CNC software can read. That wouldn't be difficult, these parts are very simple.

If you would have made this thread two weeks ago, I could have done these parts for you in Inventor (not the milling, but the models and drawings). But they'd be very simple to make on a manual lathe.

Erasmus · Jun 15, 2008

LukeA said:
I have experience CNC cutting parts drawn in Autodesk Inventor. The process is identical for SolidWorks. Using those programs, as you design parts, which you do using a technique called constructive solid geometry, you impart data into the model that allows the model file to be processed by CNC software into g-codes for the machine. SketchUp doesn't do this. To cut these parts out of metal with a CNC machine, they would have to be redrawn in a program that can export a filetype that the CNC software can read. That wouldn't be difficult, these parts are very simple.

If you would have made this thread two weeks ago, I could have done these parts for you in Inventor (not the milling, but the models and drawings). But they'd be very simple to make on a manual lathe.

Thanks for your advice, through my university I can get a free license and full version download for Autodesk Inventor, I will download it tomorrow in the library. 5 GB is quite a lot to download!

allburger · Jun 16, 2008

this is an awesome heatsink. I would love for someone to produce this and make it available in a decent quantity

Mirage_Man · Jun 16, 2008

Just finished it. And yes Will it did take about 3 hours. I had to whittle down a piece of 2.5" stock to make it because that's all I had around that was big enough.

darkzero · Jun 16, 2008

oo: :twothumbs

Erasmus · Jun 16, 2008

Mirage_Man said:
Just finished it. And yes Will it did take about 3 hours. I had to whittle down a piece of 2.5" stock to make it because that's all I had around that was big enough.

I can not believe my eyes, this is so amazing! Exactly like the drawing and the finish looks gorgeous! Looks like it's polished

This is truly incredible! PM sent

I really hope this is the one with adjusted measurements (48.2mm instead of 48.0mm and 34.2mm instead of 34.0mm).

Cheers!!!

allburger · Jun 16, 2008

Oh man, that sure was quick. Now lets see it in action

James35 · Jun 16, 2008

Now that is going to dissipate some heat! Good job! Must be nice having access to equipment like that.

rizky_p · Jun 16, 2008

WOW really clean job on the lathe, is it polished?

d1dd1 · Jun 17, 2008

Great job !
Maybe you could add threads to screw it in the Mag head like modamags PTS2-D sink which I used for my 7xQ5 Mag-mod
https://www.candlepowerforums.com/threads/107059

Erasmus · Jun 17, 2008

d1dd1 said:
Great job !
Maybe you could add threads to screw it in the Mag head like modamags PTS2-D sink which I used for my 7xQ5 Mag-mod
https://www.candlepowerforums.com/threads/107059

Thanks for the tip. I already have thought about some improvements which I will publish soon.

AlexGT · Jun 17, 2008

Will this design loose the focusing ability of the light?

cmacclel · Jun 17, 2008

AlexGT said:
Will this design loose the focusing ability of the light?

Its for 7 LED's.

Mac

cmacclel · Jun 17, 2008

d1dd1 said:
Great job !
Maybe you could add threads to screw it in the Mag head like modamags PTS2-D sink which I used for my 7xQ5 Mag-mod
https://www.candlepowerforums.com/threads/107059

Like this

http://images30.fotki.com/v472/photos/1/141020/5501007/IMG_0169-vi.jpg

Mac

Aircraft800 · Jun 18, 2008

I used 7 McR-16-XR reflectors in my Laser Engraved 7 Cree XR-E Mod shown in my avatar.

I did not have to dremel the reflectors, I just had the seat in the head lowered by .040" as seen here:

thanks to cmacclel for the idea, and machining suggestions.

I used the threaded modamag perfect sink, and sanded it flat. The new sink you are building would offer better heat dissipation.

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