This is the first mag mod I have done beyond placing a mag led upgrade bulb in my 4D. I think that the title explains most of this project. I came up with the idea when I found a switch that would turn on two different leds or sets of leds separately. With switch being where the whole idea started, this is where the project began.
The switch is a four position switch made by Judco. It is off--main led on--all leds on--secondary leds on.
I broke out the Dremel making this switch fit inside the mag housing.
The common contact is soldered to the positive plate at the bottom of the switch.
Now at this point I still haven't decided on the color of the host. I know it will be a 3D but it was between digicamo and dark green.
I then started working on the reflectors, knowing the switch will fit. I used stock mag reflectors for this. First, I cut up a reflector and epoxied its remains into another reflector. Second, I cut both reflectors down to the correct height and epoxied them to the outside of the main reflector.
I had decided on six red 5mm Cree leds, so now came drilling the holes evenly spaced. They didn't come out perfect but pretty dang close.
Fellow Cpfer, Inliner then clear coated the reflector making it a LOP to almost MOP and the leds were epoxied in.
I had finally decided on the dark green 3D and ordered a H22A heatsink. The main led is a XPG R4 5000K Outdoor White pushed by a 1.4A AMC7135 driver. The secondary leds will be DD through a resistor.
The host arrived and the switch was installed. Tightening the hex screw was a small challenge, but was accomplished through a small gap I had left in the top of the switch and a cutoff allen wrench.
Now I had to have patience……first, for the heatsink………….then for KD. Luckily the parts arrived within a few days of each other.
After installing the 5mm leds I knew my design had a small flaw. I should have placed the led shelf a little closer to the front of the reflector. The bottom of the leds were bottoming out in a black mag head I have, but I did luck out with the dark green host…the bottom of the leds barley cleared. This problem still haunted later on. The reflector was unable to slide all the way down into the heatsink. This time the heatsink had to be ground down just leaving enough of a lip to keep it at the top of the tube.
Everything in the end came together nicely in the end…
…and there was light.
The switch is a four position switch made by Judco. It is off--main led on--all leds on--secondary leds on.
I broke out the Dremel making this switch fit inside the mag housing.
The common contact is soldered to the positive plate at the bottom of the switch.
Now at this point I still haven't decided on the color of the host. I know it will be a 3D but it was between digicamo and dark green.
I then started working on the reflectors, knowing the switch will fit. I used stock mag reflectors for this. First, I cut up a reflector and epoxied its remains into another reflector. Second, I cut both reflectors down to the correct height and epoxied them to the outside of the main reflector.
I had decided on six red 5mm Cree leds, so now came drilling the holes evenly spaced. They didn't come out perfect but pretty dang close.
Fellow Cpfer, Inliner then clear coated the reflector making it a LOP to almost MOP and the leds were epoxied in.
I had finally decided on the dark green 3D and ordered a H22A heatsink. The main led is a XPG R4 5000K Outdoor White pushed by a 1.4A AMC7135 driver. The secondary leds will be DD through a resistor.
The host arrived and the switch was installed. Tightening the hex screw was a small challenge, but was accomplished through a small gap I had left in the top of the switch and a cutoff allen wrench.
Now I had to have patience……first, for the heatsink………….then for KD. Luckily the parts arrived within a few days of each other.
After installing the 5mm leds I knew my design had a small flaw. I should have placed the led shelf a little closer to the front of the reflector. The bottom of the leds were bottoming out in a black mag head I have, but I did luck out with the dark green host…the bottom of the leds barley cleared. This problem still haunted later on. The reflector was unable to slide all the way down into the heatsink. This time the heatsink had to be ground down just leaving enough of a lip to keep it at the top of the tube.
Everything in the end came together nicely in the end…
…and there was light.
