Build Log: '50' 4xXP-G

Many lessons have been learnt about design for manufacture. I am pleased to present my attempt at a 4xXP-G light. I have been trying to perfect a light with styling I like and at a price that is affordable (Think, $69AUD for a base kit) also, it will most likely have a flashlight battery pack option.

About 920 Lumen's @ 1A
Weight: sub ~110 Grams
Dimensions: 50mm OD x 38mm (Major Length, or 42mm overall) TINY!
Heatsink: 18 inch^2 of sink surface area. (So can handle 1.5A)
Completely sealed, double O-Ring and waterproof to at least IP67 (Omron switch)

I know this lumen range is already occupied by numerous many 'cheap' lights, all promising the world. but my hope is that the quality of this light will be significantly higher

Plus, like all my designs, I am taking an "Open-Source" approach. There will be no secrets, no propriety designs just an awesome light! If you ask me nicely, I will supply full engineering drawings!









It will use the most efficient of everything I could find that is readily available and in stock in large numbers.

PCB - http://www.cutter.com.au/proddetail.php?prod=cut950

Optic - Ledil GT4-XE (90% efficiency) http://www.ledil.com/datasheets/DataSheet_GT4-XP.pdf

Driver - Maxflex http://www.taskled.com/maxflex.html

that looks like a nice and simple, yet rugged design!
those taskLED drivers are excellent.

will you be selling pre-made models?

csshih said:

that looks like a nice and simple, yet rugged design!
those taskLED drivers are excellent.

will you be selling pre-made models?

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Most Likely! I wanted to downsize in cost, so I could offer this.

I built it to be strong!

Details of rear plate and seal.

csshih said:

that looks like a nice and simple, yet rugged design!
those taskLED drivers are excellent.

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+1

matthewm said:

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Can you please share more information for the front part of the head where the lens/o-ring meet the housing?

I am envious of your solid works skills every time I see your new projects. Someday I will be that good I hope

wquiles said:

+1
Can you please share more information for the front part of the head where the lens/o-ring meet the housing?

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What do you want to know? The Optic has a plastic ring around the outside, between the front panel and this is an o-ring. This design does not utilize a lens.

matthewm said:

What do you want to know? The Optic has a plastic ring around the outside, between the front panel and this is an o-ring. This design does not utilize a lens.

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That was it - you just answered my questions. I just could not quite tell from the image you posted, so I could not see that the optic had the ring built-in - thanks :thumbsup:

Mettee said:

I am envious of your solid works skills every time I see your new projects. Someday I will be that good I hope

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http://www.amazon.com/SolidWorks-2010-Bible-Matt-Lombard/dp/0470554819

Is there any interest in this design at $69AUD for a full kit?

Everything except the LED's and Driver, these would be available as an optional extra.
LED ~$38AUD
Driver ~$35USD
Optic ~$5.45AUD (I'm looking for a cheaper source!)

Hi,
in short - Absolutely....

Cheers
Mark

Where do I pay my deposit?

I'm thinking mounting it as a secondary light on a HID spotlight. 5000 lumen primary and 900 lumen secondary should be quite impressive...

With your config, would the Maxflex driver take a 12-13V input so I could power it from the SLA onboard my spotlight?

I keep on having this problem every time I design a round light; There isn't a nice way to mount the damm thing!

Here is an example Delrin mounting adapter for a cateye mount. I like it, but I don't really want to drill into the case like this. Ideally some sort of clip would be better.

matthewm said:

Is there any interest in this design at $69AUD for a full kit?

Everything except the LED's and Driver, these would be available as an optional extra.
LED ~$38AUD
Driver ~$35USD
Optic ~$5.45AUD (I'm looking for a cheaper source!)

Click to expand...

:naughty: yep, definately amateur for it: kit, LED, driver, optics
PM me if you need a pre-participation

looking at your previous drawings, do you also have other kits (a double one) available?

Hmmm nice design ... everything included would be 147.45Aud$ To much for me ...