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Thread: The Most Challenging Light Yet--to machine, that is--The TKO

  1. #1
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    Default The Most Challenging Light Yet--to machine, that is--The TKO



    EDIT: Some renderings added





    So, as you can see the grooves will be anodized blue while the flat "Islands" will be bare, shiny Ti.
    Last edited by PhotonFanatic; 12-16-2012 at 11:06 AM.
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    Flashaholic* KuanR's Avatar
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    Default Re: The Most Challenging Light Yet--to machine, that is

    Can't wait to see more pictures and the finished product, Fred
    I'm Ryan.

  3. #3
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    Default Re: The Most Challenging Light Yet--to machine, that is

    ...oh yes, that looks really cool!

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    Flashaholic* AnAppleSnail's Avatar
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    Default Re: The Most Challenging Light Yet--to machine, that is

    Holy moly! That is terrific.
    My biggest light-hog is my camera.

  5. #5

    Default Re: The Most Challenging Light Yet--to machine, that is

    Looks very impressive!

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    Flashaholic* samuraishot's Avatar
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    Default Re: The Most Challenging Light Yet--to machine, that is

    Man, you've got some skills, I can't wait to see the final product!

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    Flashaholic* Obijuan Kenobe's Avatar
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    Default Re: The Most Challenging Light Yet--to machine, that is

    I love it already.

    obi
    Stay sharp and bright for life.
    Have your knife and light handy at all times.
    Sent from a long time ago, in a galaxy far, far away.

  8. #8

    Default Re: The Most Challenging Light Yet--to machine, that is

    Wow I wondered how many machining hours it will take just to get this finished...
    ISO --> any vintage, cross-hair logo Surefire; Ku's SWM V-series 18500 tubes; PM me if you have a SPY007 XM-L2 SWGG for trade!


  9. #9
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    Default Re: The Most Challenging Light Yet--to machine, that is

    Quote Originally Posted by Silgt View Post
    Wow I wondered how many machining hours it will take just to get this finished...
    Since the material is Titanium, and with the cuts into the material at 4mm deep, then each groove required many, many passes to get to final depth. I'd guess that I have at least 15 hours of machining time into the two pieces so far. The good news, from my perspective, is that the remaining work won't take nearly as long.



    Lots of grooves there, along with some chamfering, drilling, boring, etc.
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    Default Re: The Most Challenging Light Yet--to machine, that is

    imagine how murderous a spiral of blocks with that cut would be
    posted by jh333233
    Dont cheat me, im expert in using crap light

  11. #11
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    Default Re: The Most Challenging Light Yet--to machine, that is

    Quote Originally Posted by 127.0.0.1 View Post
    imagine how murderous a spiral of blocks with that cut would be
    If you buy me a CNC lathe with live tooling, I'd be glad to make one for you--with spirals.
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  12. #12

    Default Re: The Most Challenging Light Yet--to machine, that is

    What a beautiful light! ANother masterpiece in the works! Is this one spoken for?

  13. #13
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    Default Re: The Most Challenging Light Yet--to machine, that is

    Quote Originally Posted by Zandar View Post
    What a beautiful light! ANother masterpiece in the works! Is this one spoken for?
    This is a proof-of-concept, prototype, trial run, call it what you will--it is not spoken for, as i haven't offered it to anyone. Plus, as is usual with the first of anything I make--it has a mistake in it--a nick on one of the islands, so it will come with the highly-prized maker's mark on it.

    In fact, I'm still designing parts of the light--like the end of the light:

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    Flashaholic* chipwillis's Avatar
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    Default Re: The Most Challenging Light Yet--to machine, that is

    Could you inform us of the size and what you plan for the light engine. Looks awesome..

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    Default Re: The Most Challenging Light Yet--to machine, that is

    Quote Originally Posted by chipwillis View Post
    Could you inform us of the size and what you plan for the light engine. Looks awesome..
    Diameter will be 28mm and the total length will be 80mm.

    Since the grooving is so deep, the inner space for the LE/heat sink and reflector is fairly small, so it doesn't make sense to use something like an XML in this light. I'm leaning toward using a Nichia 219, and possibly just a single mode driver, although I could use something like the Bitz driver instead.
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    Default Re: The Most Challenging Light Yet--to machine, that is

    light looks NSFM

    (not safe for mittens)
    posted by jh333233
    Dont cheat me, im expert in using crap light

  17. #17
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    Default Re: The Most Challenging Light Yet--to machine, that is

    Quote Originally Posted by 127.0.0.1 View Post
    light looks NSFM

    (not safe for mittens)
    That's quite true for the moment, but all the sharp edges will be greatly reduced in the final version.

    In the meantime, I'm continuing to work on the TKO:



    That shows the two sets of threads within the head of the light--one for the LE and the threads closest to the viewer are for the battery tube.



    And a shot that I never get tired of taking--the two pieces threaded together.

    One of the goals when designing a twisty, is to try to minimize, or hide the seam where the two pieces join together; I think the TKO gets an A+ for its deceptiveness.



    Yes, the seam is there--somewhere.



    Showing the front bevel to the lens. Still some work to be done here--first I need to complete the O-ring groove on the top of the light--on the inside--where the lens meets the light; and then, I'll enhance the bevel a bit, make it steeper, and clean up the sharp edges on the air vent holes.
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    Flashaholic* Obijuan Kenobe's Avatar
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    Default Re: The Most Challenging Light Yet--to machine, that is

    It is simply your best work yet, without a doubt. This design showcases your attention to detail, and your 3D imagination as a designer...and skills as a machinist.

    So many great things happening here, and this is only in photographs. Anyone who has never held one of Fred's lights will have a hard time imagining what level these pieces are at. The way his seams disappear is like alien technology, and the finished product is always packed with fine details that he takes for granted as the maker.

    There is a thread around here showcasing a thinking fob made by Fred. In my humble opinion, all of Fred's light qualify as thinking fobs, as they speak as much to the hand as they do to the eye. I have no doubt this is true with the TKO as well.

    Here's to ya, Fred.

    obi
    Stay sharp and bright for life.
    Have your knife and light handy at all times.
    Sent from a long time ago, in a galaxy far, far away.

  19. #19

    Default Re: The Most Challenging Light Yet--to machine, that is

    Quote Originally Posted by Obijuan Kenobe View Post
    ...So many great things happening here...
    You got that right!

    Fred, I must have hiding under a rock because this one's hard to ignore...
    ...can't wait to see it anodized (and may the force be with you for that phase of this "little" project of yours...)
    Traveller - Genève * Melbourne * Miami * Wien

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  20. #20
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    Default Re: The Most Challenging Light Yet--to machine, that is

    Thanks, guys.

    Just received a new, higher amperage power supply to make the anodizing a bit easier, and hopefully more consistent.

    Need to machine some Ti pieces which will be the interface between the copper wires from the power supply to the part. Can't let the copper reach the anodizing solution!
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    Flashaholic* tobrien's Avatar
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    Default Re: The Most Challenging Light Yet--to machine, that is

    that looks spectacular
    aka Edgar Allan Bro, Brosama Bin Liftin, Walter Crunkite, Bro Namath, Teddy Brosevelt, and the Tomahawk Crunkmissile.
    my lights - review of PrecisionWorks - that's Gucci Mane in my avatar

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    Flashaholic* gollum's Avatar
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    Default Re: The Most Challenging Light Yet--to machine, that is

    brilliant work

    always pushing the boundaries

    thanks for showing

  23. #23
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    Default Re: The Most Challenging Light Yet--to machine, that is

    Amazing workmanship. I shudder to think how hard it would be to clean that light, though. You'd need to use pipe cleaner, or something.

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    Flashaholic* AnAppleSnail's Avatar
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    Default Re: The Most Challenging Light Yet--to machine, that is

    Just a sec, guys. I need to brush my flashlight's teeth.
    My biggest light-hog is my camera.

  25. #25
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    Default Re: The Most Challenging Light Yet--to machine, that is

    Quote Originally Posted by fyrstormer View Post
    Amazing workmanship. I shudder to think how hard it would be to clean that light, though. You'd need to use pipe cleaner, or something.
    I'd just keep it wrapped in Saran Wrap all the time.
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    Default Re: The Most Challenging Light Yet--to machine, that is

    Quote Originally Posted by PhotonFanatic View Post
    I'd just keep it wrapped in Saran Wrap all the time.
    Bah. That's like taking a shower with a raincoat on.

  27. #27
    Flashaholic RIDE's Avatar
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    Default Re: The Most Challenging Light Yet--to machine, that is

    Another amazingly beautiful creation Fred!

    RIDE

  28. #28
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    Default Re: The Most Challenging Light Yet--to machine, that is

    Finally got all the elements in place to enable the anodizing of the two pieces:



    Color is really a bit more blue green than the photo shows, but good enough to represent the color of the ocean somewhere.


    Next up with be the Great Revealing--machining down the squares to create the silver 'islands' floating in the blue-green ocean. Helps to have a vivid imagination here.
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  29. #29

    Default Re: The Most Challenging Light Yet--to machine, that is

    Quote Originally Posted by PhotonFanatic View Post
    ...Color is really a bit more blue green than the photo shows... Next up with be the Great Revealing--machining down the squares...
    OMG Fred, that looks fantastic - can't wait to see it in two-tone...

    Bet it's gonna blow us all away...
    Traveller - Genève * Melbourne * Miami * Wien

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  30. #30
    Flashaholic* gollum's Avatar
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    Default Re: The Most Challenging Light Yet--to machine, that is

    Beautiful work Fred
    thanks for showing

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