This has been a long time in the making, but finally, thanks to mikesantor, who risked an E-series head by drilling out the reflector hole, I am able to show off Mike's E1E with XML U2 drop-in.
In order to fit the XML emitter in the head, the reflector hole was drilled to enlarge the diameter to 9/32", allowing me to make a heatsink with a big enough post diameter to hold the emitter. Once I figured out how to make a PCB that would fit soldering pads in the limited space left on top, we were in business, but not before having to re-work the depth of the driver pocket (oops). I'm really impressed with how it turned out.
Specs:
Driver:
2.8amp 8x7135 driver with custom programmed uC to give a moonlight mode in addition to the 3 stock modes
Emitter: Cree XML U2 flux bin, 1C tint
Heatsink/PCB: copper heatsink with custom pcb that is only 0.010" thick, with a hole under the emitter to allow direct soldering of emitter to copper heatsink
Host: E1E bored by PrecisionWorks to fit 18mm cells, and reflector opening drilled out to 9/32" diameter
I will let Mike give performance specifics, I'm biased when it comes to the performance of the light. Suffice to say I'm glad Mike put me up to this by drilling his own E-series head, as I was too scared to do something like that for fear that the reflective surface would be damaged. It turned out fine in his hands.
Pics are poor quality and rushed, I will try to get some better ones up if I can, or let Mike get some good ones to post.
In order to fit the XML emitter in the head, the reflector hole was drilled to enlarge the diameter to 9/32", allowing me to make a heatsink with a big enough post diameter to hold the emitter. Once I figured out how to make a PCB that would fit soldering pads in the limited space left on top, we were in business, but not before having to re-work the depth of the driver pocket (oops). I'm really impressed with how it turned out.
Specs:
Driver:
2.8amp 8x7135 driver with custom programmed uC to give a moonlight mode in addition to the 3 stock modes
Emitter: Cree XML U2 flux bin, 1C tint
Heatsink/PCB: copper heatsink with custom pcb that is only 0.010" thick, with a hole under the emitter to allow direct soldering of emitter to copper heatsink
Host: E1E bored by PrecisionWorks to fit 18mm cells, and reflector opening drilled out to 9/32" diameter
I will let Mike give performance specifics, I'm biased when it comes to the performance of the light. Suffice to say I'm glad Mike put me up to this by drilling his own E-series head, as I was too scared to do something like that for fear that the reflective surface would be damaged. It turned out fine in his hands.
Pics are poor quality and rushed, I will try to get some better ones up if I can, or let Mike get some good ones to post.