My latest EDC projects (lots of large pictures)

I've built a couple of EDCs using the X-Light Micro as a base, with small Lipo batteries and 5mm LEDs but, as would be expected, always wanted something equally pocketable but with more power.

I don't have access to a machine shop to build something akin to Saberwolfs excellent Chimera but I do have sheet metal working equipment and after lots of trial and a lots and lots of error, I came up with the light detailed below.

Measurements are length 58mm, width 43mm, height 11.7mm and weighs in at a svelte 1.6 ounces. The body and lid are aluminum with the body made from .02" and the lid .05" sheet.

Trimmed aspheric lens, not sure of the focal point but at the highest peak it is 8mm deep.

The LED is a XML, I don't have the bin number but looks to be in the neutral range.

The lipo charger uses the newer MCP73831T and will feed the battery up to 500mah depending on the supply capability.

The X-Light Micro circuit controls a mosfet that supplies juice to the XML.

The battery protection circuit for the lipo kicks in at around 2000mah of draw so I have max power limited to 1700mah at full charge. The light does get pretty warm running at high for any length of time but not hot enough to damage anything.

I did a lot of research on the switch and how to keep it from accidentally turning on while in a pocket with keys, change, etc. Found that by using the soft silicone cover, recessing the clicker and making the switch hole slightly smaller than standard worked very well. So far, after more than a month of daily carry and usage, I have never had an accidental power up.


http://i818.photobucket.com/albums/zz107/sunny_nites/PB190015.jpg


This is the heart of the light; 850mah lipo from a cell phone (hard metal case, not prismatic bag) and the X-Light Micro controller.
http://i818.photobucket.com/albums/zz107/sunny_nites/PA121328.jpg


XML providing the lumens:
http://i818.photobucket.com/albums/zz107/sunny_nites/PB190018.jpg


Blue beacon or locator running at 10micro amps, glowing up the Aspheric lens. From experience I can say this is a very useful feature:
http://i818.photobucket.com/albums/zz107/sunny_nites/PB190019.jpg


Standard Micro USB charge connector with LED activity indicator:
http://i818.photobucket.com/albums/zz107/sunny_nites/PB190024.jpg

Taking a charge from a wireless charger:
http://i818.photobucket.com/albums/zz107/sunny_nites/PB190012.jpg

I intentionally went with a floody focus as this is intended for pocket or key chain duty and I personally find a flood more useful than a spot.
This is on high around 15 feed from the wall:
http://i818.photobucket.com/albums/zz107/sunny_nites/PB190003.jpg


Really hard to get a shot on low but this is how it looks at the business end:
http://i818.photobucket.com/albums/zz107/sunny_nites/PB190001.jpg


Compared to an Ipod to give you a rough idea of the size:
http://i818.photobucket.com/albums/zz107/sunny_nites/PB190002.jpg


I had intended on painting it black but after carrying it around for over a month now, I really got used to it being raw aluminum and think I will just leave it that way. For the next one I am working on (there is always "next one", isn't there?) I will use an aluminum filled epoxy to blend the seams in better.

I also will be using a 1300mah battery and will run the XML at something over 2000mah.

You may have noticed the wireless charger in the picture above. The next version will feature wireless charging using this circuit:
http://i818.photobucket.com/albums/zz107/sunny_nites/PB1900022.jpg


Made another out of copper and silver solder. I like the way it looks but had to coat it with urethane to keep the copper from instantly tarnishing:
http://i818.photobucket.com/albums/zz107/sunny_nites/PB021347.jpg


I used a XR-E (yeah, I know; ewwwwww) running at 750mah max and moved the lens farther away from the LED for more throw. Same target as with the XML but you can see it has a much tighter, albeit dimmer, beam.
http://i818.photobucket.com/albums/zz107/sunny_nites/PB0213462.jpg


Thanks for looking!

(lots of large pictures) = Lots of oversize pictures


Your images are too large and have been replaced with links Please resize and repost.
See Rule #3 If you post an image in your post, please downsize the image to no larger than 800 x 800 pixels. - Thanks Norm

Nice project... Congrats...


Sent from my phone with camera with flash and internet on it...

Thanks!

I went ahead and painted the aluminum light black.

Used semi gloss epoxy, like what would typically be used on an appliance (stove, fridge, etc). That stuff is pretty tough and hopefully will wear well.

Been carrying it painted for a couple of weeks now and so far so good.



(400x400 matrix. My apologies, Norm)