Rayovac 4D-B modification.

Let the mod begin...

I´m thinking to mod this
an Rayovac 4D-B, use 6v Krypton bulb.



using a 100w led and 4 x 18650 batteries :naughty:
and one of this:

do it.

the led with heatsynk reflector and lens.



REflector to be cuted

unfortunately did not take photo using the original bulb for later comparison.




put the dremel cutting disk to an drill press



let the game begin

reflector en led set together




led without reflector and lens





in preliminar tests the light is more concentrated in a point without the reflector and lens,
the focal point of the flaslight reflector is just on the led surface without the lens (is the distance where de bulb went; the area cutted)
i decided to use it that way.

other point is: i have to extend the body of the flashlight, the heatsink and fan dont fit inside.

and now i´m running out of time, this morning i have been informed that this friday i have to go camping.:naughty:
excelent opportunity to make some tests XD.:twothumbs

Will you be cutting vent holes in the flashlight body?

The fan might be pointless otherwise.

yes, ventilation holes will be needed,
because, like i said before, i´m running out of time, and i had to make some changes to the original idea that was to extend the body with metal mesh or something.
i had to use a different heatsink that fits inside the original body.



there you can see my custom battery pack, i made frames with laser cutted acrylic,
and the plug for the charging circuit


i made some modification to the booster heatsink




Here are all together inside

i found out that reducing the output voltage of the booster to 27v, the led only consume 670mAh, and the fan will not be needed, i turned it on for 10 minutes continuous, the battery only drops near 2 volts, the led does not emit too much heat, the light is less but still rocks



any way, i´ll drill the vent holes and set the voltage like it supposed to be, then :naughty: I´ll carry a bit of the sun in my backpack

27 x 0.670, that's like 18 watts. Pretty much the same as an MT-G2. I wonder what lumens that cranks out, if it's the same as an MT-G2.


Meanwhile, what do you mean by the batteries drop 2 volts?

That MT-G2 is amazing XD.
some day i´ll try it

about the batteries, i mean, fully charged it has 16.8v, after the time testing, it measures 14.3v

i dont know about lumens, but a 100 watt led is about 10,000 or 9,000 lumens, if i can get even 5,000lm i´ll be pleased

i forgot to take the pictures while i was camping ,