HDS Systems        
Page 2 of 3 FirstFirst 123 LastLast
Results 31 to 60 of 87

Thread: WIP: Tungsten Flashlight

  1. #31
    Moderator
    archimedes's Avatar
    Join Date
    Nov 2010
    Location
    CONUS, top left
    Posts
    13,387

    Default Re: Tungsten Flashlight, or something else?

    Quote Originally Posted by fl0t View Post
    tungsten CR2 fatty!

    A tungsten flashlight, has it been done before?
    Yes, the quasi-mythical LarryLight, in W ....
    ... is the archimedes peak

  2. #32
    Flashaholic* jamesmtl514's Avatar
    Join Date
    Oct 2009
    Location
    Montreal, Canada
    Posts
    1,841

    Default Re: Tungsten Flashlight, or something else?

    And Macs EDC
    My lightsWTB: Surefire: New/Used/Rare. Currently looking for everything Crosshairs + D2. Interesting trades available.Everybody, just send your lights directly to James - he'll end up with them anyhow, lol. -Kestrel

  3. #33
    Moderator
    archimedes's Avatar
    Join Date
    Nov 2010
    Location
    CONUS, top left
    Posts
    13,387

    Default Re: Tungsten Flashlight, or something else?

    Quote Originally Posted by jamesmtl514 View Post
    And Macs EDC
    I thought those were "Tungsten"(-colored-grey) Cerakote ??
    ... is the archimedes peak

  4. #34
    Flashaholic*
    Join Date
    Dec 2003
    Location
    western Massachusetts
    Posts
    2,336

    Default Re: Tungsten Flashlight, or something else?

    Quote Originally Posted by archimedes View Post
    I thought those were "Tungsten"(-colored-grey) Cerakote ??
    I think you are correct; the only Tungsten light that I've read about was Larry's light.
    PhotonFanatic—fanatic@photonfanatic.com
    CPF Custom Builders and Modders
    My Blog

  5. #35
    Enlightened
    Join Date
    Dec 2012
    Location
    Calgary
    Posts
    59

    Default Re: Tungsten Flashlight, or something else?

    Very curious to see this materialze.

  6. #36
    Flashaholic
    Join Date
    Oct 2009
    Location
    Oxford, CT
    Posts
    255

    Default Re: Tungsten Flashlight, or something else?

    awesome!

    You have found a real niche market! These would sell like hot Krispy Kremes.

  7. #37
    Flashaholic* Mattaus's Avatar
    Join Date
    Mar 2011
    Location
    Brisbane, Australia
    Posts
    1,765

    Default Re: Tungsten Flashlight, or something else?

    So is it knurled or will those patterns be machined? I'm obviously interested to see how that turns out...

  8. #38
    Flashaholic* KuanR's Avatar
    Join Date
    Jan 2012
    Location
    Macau S.A.R.
    Posts
    1,802

    Default Re: Tungsten Flashlight, or something else?

    Quote Originally Posted by PhotonFanatic View Post
    I think you are correct; the only Tungsten light that I've read about was Larry's light.
    Don't quote me on this, but I recall reading somewhere on the forum Mac made a one-off EDC SST-50 in actual W, not tungsten coated.

    I really want to see how this looks when finished, and how it looks compared to titanium
    I'm Ryan.

  9. #39
    Flashaholic*
    Join Date
    Dec 2003
    Location
    western Massachusetts
    Posts
    2,336

    Default Re: Tungsten Flashlight, or something else?

    Matt: The pattern will be milled into the surface, not knurled.

    Ryan: You could be right--I really don't know if Mac made one or not.

    And now I'll turn this thread into a WIP thread. Admittedly, I haven't gotten very far on the machining of the light, but I have started.



    Here's the 1" square stock in the four-jaw chuck; and, yeah, it does stick out more than I would like, but I am taking light cuts.

    Tungsten seems fairly nice to machine, at least this alloy, which is 95% W and some other element. Unlike Ti, W makes small chips, not long strings, and it does not work harden. I suspect that getting a super smooth shiny surface will not be in the cards, however.



    Here I've taken a good portion of the bar down to 25.4mm diameter, or 1". At this point, I remove the piece from the four-jaw chuck and place the turned down end into a collet.



    Once in the collet, I can now turn down the remaining square portion of the bar.

    After the entire bar had been reduced to 1" diameter, I drilled and bored the interior to 17mm, so that I could insert an expandible collet into the piece. That would allow me to access the entire length of the bar, now about 57mm, in one continuous pass.



    So, the turning operation continued until the OD of the entire bar is now just slightly larger than 21mm, which will be the final diameter of the light.

    Next operation will be to split the part, parting off what will be the battery tube. Then I'll drill and bore out the battery tube so that it can be placed on another expandable collet. From there I can then proceed to cutting the axial grooves and circumferential grooves that will create the squares.
    PhotonFanatic—fanatic@photonfanatic.com
    CPF Custom Builders and Modders
    My Blog

  10. #40
    Flashaholic* KuanR's Avatar
    Join Date
    Jan 2012
    Location
    Macau S.A.R.
    Posts
    1,802

    Default Re: Tungsten Flashlight, or something else?

    I don't know how to describe those pictures....it looks....delicious
    I'm Ryan.

  11. #41
    Flashaholic*
    Join Date
    Dec 2003
    Location
    western Massachusetts
    Posts
    2,336

    Default Re: Tungsten Flashlight, or something else?

    Quote Originally Posted by KuanR View Post
    I don't know how to describe those pictures....it looks....delicious
    You must like some weird foods--it looks like a dull gray piece of metal to me.
    PhotonFanatic—fanatic@photonfanatic.com
    CPF Custom Builders and Modders
    My Blog

  12. #42
    Flashaholic*
    Join Date
    Dec 2003
    Location
    western Massachusetts
    Posts
    2,336

    Default Re: Tungsten Flashlight, or something else?

    A little more progress, after a lot of work and learning.

    One thing any machinist should know is that it takes a while to learn how to machine a metal that one hasn't worked on before. Sure, you can read the books for speed and feed recommendations, but until you've spent some time cutting a particular metal, you really can't be 100% sure that you are going to do it right. So practice makes perfect, eventually. Unfortunately, since I don't have any more Tungsten to play with and learn, I have to learn while trying to make a light.

    And it didn't take long to realize that I really didn't know how to part off Tungsten:



    That was perhaps only another try away from going drastically wrong--too much chatter, the material pulls the cutting edge into itself, and, voila, the tool broke. Thank goodness it broke, rather than having the piece climb over the tool and thoroughly ruin the piece.

    So, what was the answer--adjust the tool height, slow down the RPMs, increase of decrease the feed rate? Hell if I know--I just got out a different, stronger tool bit and proceeded with a very soft touch as I fed the tool into the material. I'll have to figure out the right settings and procedure when I get some more Tungsten to play with.

    In any event, this was a most welcome sight:



    Head of the light on the right and the battery tube still in the four-jaw chuck.

    Then I had to bore out the battery tube, close to the diameter needed for the battery, but primarily so that I can get an expandable collet in the battery tube, to allow me to machine the squares on the OD.



    Boring out the battery tube--just about done.

    The next few days will be spent cutting the squares in both the head and the battery tube. How do I know it will take days? Simple--it took me one and a half hours just to do the axial cuts in the head of the light--but that's only to half the eventual depth of cut. At that rate, each piece would take 6 hours for just the machining of the squares.

    However, I do think that machining the circumferential grooves won't take as long--a good part of the metal will already have been removed--still, they will certainly take a while.



    Go ahead and count them--27 grooves, to save you some time. That's half way to the final depth of cut.
    PhotonFanatic—fanatic@photonfanatic.com
    CPF Custom Builders and Modders
    My Blog

  13. #43
    Flashaholic* Mattaus's Avatar
    Join Date
    Mar 2011
    Location
    Brisbane, Australia
    Posts
    1,765

    Default Re: Tungsten Flashlight, or something else?

    Forgive my ignorance, and maybe I missed it somewhere, but why only half depth cuts? Preserve the cutting tool? Stop the tool from gouging?

  14. #44
    Flashaholic*
    Join Date
    Dec 2003
    Location
    western Massachusetts
    Posts
    2,336

    Default Re: Tungsten Flashlight, or something else?

    Quote Originally Posted by Mattaus View Post
    Forgive my ignorance, and maybe I missed it somewhere, but why only half depth cuts? Preserve the cutting tool? Stop the tool from gouging?
    Hey, Matt--I don't think I'd ever consider you to be ignorant.

    Cutting to the full depth of cut, which in this case would be 0.70mm would put too much of a load on the cutting tool, which most likely would lead to a lot of heat and a much shortened life for the cutting edges.

    Plus, it's just the way I prefer to machine--never too much of anything at once--light cuts, moderate speeds, etc.
    PhotonFanatic—fanatic@photonfanatic.com
    CPF Custom Builders and Modders
    My Blog

  15. #45
    Flashaholic* Mattaus's Avatar
    Join Date
    Mar 2011
    Location
    Brisbane, Australia
    Posts
    1,765

    Default Re: Tungsten Flashlight, or something else?

    I guess when you have nothing to experiment with it pays to be careful. Ah patience....I could learn a thing or too haha.

  16. #46
    Flashaholic*
    Join Date
    Dec 2003
    Location
    western Massachusetts
    Posts
    2,336

    Default Re: Tungsten Flashlight, or something else?

    Did I say that I didn't think Tungsten would not be shiny??



    I must say that the more I work with Tungsten, the more I like it.

    Now that the head has been decorate, I hope to start work on the battery tube on Monday.
    PhotonFanatic—fanatic@photonfanatic.com
    CPF Custom Builders and Modders
    My Blog

  17. #47
    Flashaholic* Mattaus's Avatar
    Join Date
    Mar 2011
    Location
    Brisbane, Australia
    Posts
    1,765

    Default Re: Tungsten Flashlight, or something else?

    Does this roll easily? Or does the pattern act as a sort of anti-roll? I guess because it's so small it'll roll easily enough with a gentle nudge.

  18. #48
    Flashaholic*
    Join Date
    Dec 2003
    Location
    western Massachusetts
    Posts
    2,336

    Default Re: Tungsten Flashlight, or something else?

    Yup, it does roll easily and makes a nice sound while doing so.
    PhotonFanatic—fanatic@photonfanatic.com
    CPF Custom Builders and Modders
    My Blog

  19. #49
    Flashaholic* KuanR's Avatar
    Join Date
    Jan 2012
    Location
    Macau S.A.R.
    Posts
    1,802

    Default Re: Tungsten Flashlight, or something else?

    DELICIOUS looking. It reminds me of a Ferrero Rocher or Almond Roca
    I'm Ryan.

  20. #50
    Flashaholic*
    Join Date
    Dec 2003
    Location
    western Massachusetts
    Posts
    2,336

    Default Re: Tungsten Flashlight, or something else?

    More akin to Toblerone; although their pyramid isn't perfectly square.
    PhotonFanatic—fanatic@photonfanatic.com
    CPF Custom Builders and Modders
    My Blog

  21. #51

    Default Re: WIP: Tungsten Flashlight

    Awesome work, really.

    I have a tungsten wedding ring, beautiful material the way it polarizes between chrome and black depending on how the light catches it. Virtually scratch proof too.

  22. #52
    Flashaholic
    Join Date
    Oct 2009
    Location
    Oxford, CT
    Posts
    255

    Default Re: WIP: Tungsten Flashlight

    Quote Originally Posted by KuanR View Post
    DELICIOUS looking. It reminds me of a Ferrero Rocher or Almond Roca
    More food references! :beer:

  23. #53
    **Do Not Feed The Vegan**
    jch79's Avatar
    Join Date
    May 2006
    Location
    On the asphalt.
    Posts
    3,660

    Default Re: WIP: Tungsten Flashlight


  24. #54
    Unenlightened
    Join Date
    Feb 2013
    Posts
    1

    Default Re: WIP: Tungsten Flashlight

    Hi people
    I have been following your thread with much interest and was disapointed to reach the end. I hope there is a lot more to come as I am in the process of building my first flashlight. Excited about creating some swarf on yhe lathe and mill.
    Cheers
    Marcus53

  25. #55

    Default Re: WIP: Tungsten Flashlight

    The head picture looks so good Im not sure if it is a rendering or the real thing


  26. #56
    Flashaholic*
    Join Date
    Dec 2003
    Location
    western Massachusetts
    Posts
    2,336

    Default Re: WIP: Tungsten Flashlight

    Quote Originally Posted by fl0t View Post
    The head picture looks so good Im not sure if it is a rendering or the real thing
    That's the real thing--it's just the lighting that makes it look so even.
    PhotonFanatic—fanatic@photonfanatic.com
    CPF Custom Builders and Modders
    My Blog

  27. #57
    Flashaholic*
    Join Date
    Dec 2003
    Location
    western Massachusetts
    Posts
    2,336

    Default Re: WIP: Tungsten Flashlight

    Quote Originally Posted by Marcus53 View Post
    Hi people
    I have been following your thread with much interest and was disapointed to reach the end. I hope there is a lot more to come as I am in the process of building my first flashlight. Excited about creating some swarf on yhe lathe and mill.
    Cheers
    Marcus53
    Oh, we are not done with the build yet. I had another job so up that needed my attention--I'll get back to this soon.
    PhotonFanatic—fanatic@photonfanatic.com
    CPF Custom Builders and Modders
    My Blog

  28. #58
    Flashaholic* DBCstm's Avatar
    Join Date
    May 2009
    Location
    Heart of Texas
    Posts
    1,488

    Default Re: WIP: Tungsten Flashlight

    I don't know how to say what needs to be said without expletives.

    Fred. Genious, sheer fn genious.

    Dale

  29. #59

    Popcorn Yes, light, light!

    Subscribed !!!
    Traveller - Genève * Melbourne * Miami * Wien

    coherency / steel-is-real

  30. #60
    Flashaholic*
    Join Date
    Dec 2003
    Location
    western Massachusetts
    Posts
    2,336

    Default Re: Yes, light, light!

    Now that I had a little time to devote to the Tungsten Mule, here are the photos showing the work on the battery tube.



    I have already bored out the interior so that I could insert an expandable collet. Then I worked on the threads. After those were done, the squares needed to be milled into the OD of the battery tube. Here I'm cutting the circumferential grooves along the bottom of the battery tube.



    Then, the 27 axial grooves needed to be milled as well. This is really time consuming, but if you want the design, then you pay the price.

    Also, by taking repeated passes along the grooves, it results in a much smoother, and therefore, shinier surface.



    At this stage, both pieces have been threaded and milled. The remaining work will be to bore out the battery tube for the right size for the CR2 battery and to make the mule LE.



    And screwed together--it's pretty obvious where they join in this photo, but when I'm done with the tweaking, that seam will practically disappear.

    One thing that delighted me today was discovering that the threads cut in this Tungsten are really nice and smooth--no roughness at all. I may not even bother to lap them, that's how smooth they are. And I attribute that to the material, not my threading.
    Last edited by PhotonFanatic; 03-12-2013 at 03:42 PM.
    PhotonFanatic—fanatic@photonfanatic.com
    CPF Custom Builders and Modders
    My Blog

Page 2 of 3 FirstFirst 123 LastLast

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •