Triple 90 CRI XM-L2 Module on Massive Copper Heatsink Stuffed in 4D Mag

Hi folks,

This Mag build is for a member here, who may identify himself if so inclined - I'm not going to blow his cover.

Using a Type-III coated 4D Mag as the host, this build will use the excellent PilotPTK fully-programmable triple XM-L2 module. This one has three 90 CRI 3000K XM-L2s, fed 3.44 amps each. AFAIK, this is the first use of the 90 CRI XM-L2s with this module.

Here's the host:





The bare module:





The optics used are the CUTE-3, a triple TIR lens. You can see three versions below, the narrow, medium, and (custom bead-blasted) frosted wide:




Here's what the module looks like with an optic in-place:




Since the module is ~34mm across, a fitment ring is needed to hold it in the larger Mag head. Here's a pic of the ring being machined out of T6061 aluminum:





Here's the trim ring, fresh off the lathe:

a


I think it looks better after a trip through the bead-blast cabinet:




Stay tuned for more...

Now, the heatsink needs to be made from this chunk of copper:




Hmmm....it doesn't quite fit in the Mag head. I think it will need to be cut down a bit:




That's a very spendy chunk of copper. I think a Delrin prototype used for fitment would be a good idea.

Here's the Delrin version being turned to the correct diameter:




Finished prototype:




It's a perfect fit. Here's what the module will look like installed:




Here's the optional frosted optic:




Stay tuned for the machining of the copper, final assembly, and beamshots.

The switch needed to be converted to momentary operation to best exploit the features of this module. Here are a few pics of that process.

Stock switch, with tower:




One bandsaw later:




Stock spring removed, and a notch cut for wire clearance:




Two holes needed to be drilled for routing the positive battery contact to the module:





The lower contact of the switch needed to be trimmed, so it no longer contacts the back of the positive spring.



More drilling to route the negative (ground) wire:





The "teeth" of the switch that allow for the switch to latch needed to be removed. The wee parts went in the lathe for this task, and an internal threading tool was used to remove the excess plastic:





Here you can see the stock version on the left, the (pre-cleanup) modded version on the right:




The stock spring was replaced with a gold-plated piece:




The positive wire was then soldered to the spring:




Here's the completed switch, wired and ready to go:




A Delrin isolation disc was cut to prevent any electrical shorts:

Here's the heatsink being turned to size:





Parting off - almost there !




Delrin prototype next to finished copper heatsink:




Shiny !




Fitment looks good:





This thing is beefy.... 14oz of solid copper goodness:



That's just shy of 400g, for the metric folk:




Final assembly and beamshots still to come.

Nice work Chicago X. Looks awesome!

Wow! very very cool. (Or warm!)

Just wondering if the optics only come in the textured versions or if there is a clear version somewhere that would work ?

I like the looks of this so far.

mvyrmnd said:

Wow! very very cool. (Or warm!)

Click to expand...

biglights said:

Nice work Chicago X. Looks awesome!

Click to expand...

Thanks, guys !

Tedfs said:

Just wondering if the optics only come in the textured versions or if there is a clear version somewhere that would work ?

I like the looks of this so far.

Click to expand...

A friend sent me a flat, polished version of these CUTE-3 optics. There was no measurable increase in throw, and a huge number of distracting artifacts introduced into the beam.

Even the narrow versions produce a "wall-of-light," suitable for close and medium-range illumination.

loving it! cant wait to see more of it.

skyfire said:

loving it! cant wait to see more of it.

Click to expand...

Thanks ! More switch mod pics in post #3.

Heatsink pics in post #4 are up.

Sweet build! Love to see the pics!

good stuff man!

Redhat703 said:

Sweet build! Love to see the pics!

Click to expand...

tobrien said:

good stuff man!

Click to expand...

Much appreciated.

The completed switch pics are up, in post #3 This one is almost done !

Does a copper heatsink that large make the light noticeably heavier on the bright end?

Gtamazing said:

Does a copper heatsink that large make the light noticeably heavier on the bright end?

Click to expand...

Heavier, yes - but not unbalanced or unwieldy. The length of the 4D helps quite a bit in this regard.

While waiting on the Arctic Silver epoxy to dry, I whipped up a few parts to make this light more cell-friendly. The owner will likely use larger cells, but these additions will make using the ubiquitous 18650 a no-hassle proposition.

First, an aluminum insert for the tailspring. This helps the large-diameter spring make contact with the smaller cells:



Here you can see the new contact area, in relation to a dummy cell:



Here is a Delrin cell holder and new billet dummy cell, which is sized to take up the excess length of the 4D body when 3 18650 cells are used:



The ~45mm dummy cell is covered in clear shrink-tubing.

It's ALIVE:




Here's a comparison between the fluorescent shop lighting and the high-CRI LEDs:

Shop:



High-CRI:



Here's a beamshot with the medium lens, from about four feet away:



Same distance, wide lens:

I have not heard from Wayne for three months now. He has not replied to phone calls, emails or private messages. He hasn't posted here, or BLF.

It's looking more and more like he's absconded with my Maglite and my deposit.