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Thread: 1?? Mcd Xenon Flashlight Project - BFF

  1. #91
    Flashaholic Enderman's Avatar
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    Default Re: 1?? Mcd Xenon Flashlight Project - BFF

    Very nice battery pack
    Soldered or spot welded cables on the batteries?

  2. #92
    Flashaholic PolarLi's Avatar
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    Default Re: 1?? Mcd Xenon Flashlight Project - BFF

    Thanks! It's soldered together - easy to disassemble when I make mistakes, this is only the third config
    I've got lux in different area codes.

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  4. #94
    Flashaholic PolarLi's Avatar
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    Default Re: 1?? Mcd Xenon Flashlight Project - BFF

    Unfortunately not any news on this project. But I'll be back when the sun goes down
    I've got lux in different area codes.

  5. #95
    Flashaholic* The_Driver's Avatar
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    Default Re: 1?? Mcd Xenon Flashlight Project - BFF

    Quote Originally Posted by PolarLi View Post
    Unfortunately not any news on this project. But I'll be back when the sun goes down
    End of July?

  6. #96
    Flashaholic PolarLi's Avatar
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    Default Re: 1?? Mcd Xenon Flashlight Project - BFF

    Quote Originally Posted by The_Driver View Post
    End of July?
    Pretty much, but I may update before, just can't say for sure right now.
    Last edited by PolarLi; 07-26-2019 at 03:03 PM.
    I've got lux in different area codes.

  7. #97
    Flashaholic PolarLi's Avatar
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    Default Re: 1?? Mcd Xenon Flashlight Project - BFF

    I'm sorry for the late update, again! I could be writing a long excuse on why, but there is no point of wasting the time. But now I'm back in business and got some things done.

    Because of the new layout inside the housing, I had to pull all the parts out except the reflector. Somewhere down the road there was made some compromises on easy access for all the fasteners, oh well..



    I had to extend the stock wires to the igniter a little bit:





    The Xenon PSU will now go in across the tube, so I had to make new brackets for it:



    The angle attachment on the dremel is handy for making new holes:



    And speaking of PSU, last week I did some fine tuning on the current, as access will be limited inside the housing, and you also have to adjust the current on the fly.



    Finally got the top handle on, so now it's offically a "flashlight"



    Had to sand out a little bit of the handle before install so it had some curve. On the inside I got to use the washers I made a long time ago:





    With the battery and PSU installed, it's starting to look like something again:



    I will now move on to install of the lamp and some temporary wiring to give it a test.
    I've got lux in different area codes.

  8. #98
    Flashaholic* The_Driver's Avatar
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    Default Re: 1?? Mcd Xenon Flashlight Project - BFF

    You have my attention!

  9. #99
    Flashaholic Enderman's Avatar
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    Default Re: 1?? Mcd Xenon Flashlight Project - BFF

    :O Exciting!

  10. #100
    Flashaholic PolarLi's Avatar
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    Default Re: 1?? Mcd Xenon Flashlight Project - BFF

    The Driver and Enderman

    After 5 weeks of drought, the weather has been volatile lately, but I eventually got some decent conditions so I fired up the light again. I realized it's been many months since I saw a light beam
    Previous to that I made some brackets I needed for the DC breaker and the AUX PSU.

    It's alive! Hopefully it's stays like that.



    These DIN rail breakers are not designed for panel mounting, so I had to make a bracket.



    Unfortunately, it became a little more complicated than necessary because I initially wanted to epoxy on the small angle brackets on the back panel to avoid visible screws. (like the picture above) But just before I was about the install it, I realized the epoxy would squeeze out and mess up the fit, so I went with one screw in each plus VHB tape. It's very solid, but since I had to use the screws, it could be made with just one piece of alu instead of three





    The bracket for the AUX PSU also had a rail mount. But here I could simply bend a piece of standard DIN rail and screw it on the side og the housing. I also bent the rail a little bit on the corner so the PSU can't slide off. The placement of this PSU gives me easy access to the terminals and short wire runs.





    Next up is making some kind of air deflector for the intake fan that cool the Xenon PSU. I also need to modify the lamp holder a little bit and a finish a few more details before I start on the wiring.
    I've got lux in different area codes.

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