Hi guys,
I designed a 38 mm diameter reflector based on the parabolic formula I am usng in my newest PR cloned reflector ( All credit and no blame go to Pelican and specifically a real gent who works there for allowing me "inside" back with the start of the PR series). Anyway, I have made one head in anticipation of getting a small and expensive prototype run of these reflectors done for evaluation and play. This built to suit host is shown below next to a 27 mm PR (I should probably start calling it a McR-27 since it is based on the PR but made for me off my own dwg) :
Well with the new reflector, I wanted to see how well it lent itself to being chopped and fitted to other hosts. My next experiment was to see how it would do in ArcMania's SF3 which sports a 30 mm optic that just doesn't float my boat. I chopped one of these down considerably to the 30 mm OD:
The results are very satisfactory. I should back up a bit and mention that the 38 mm when compared to a McR-27 gives a slightly tighter beam and on the same LED source (DB917) yielded a 4800+ lux at one meter in comparison to the 2400 lux from the 27. I believe it is safe to assume that as the 38 gets peared down towards the 27, both the beam and lux will approach that of the 27; it's the same reflective surface after all. So anyway, in the ArcMania SF-3, the beam is tighter and presumably brighter than a 27 mm host would be. I like seeing the head filed to capacity with a light engine and not the white frame of the 30 mm optic.
I wanted to see how this 38 would act on a 5W and instead of making a 5W ES module for the 38 proto head, I decided to get some more "chopping" experience as well as use a dead KL 2 that PK had given me. This would also give me a chance to compare the 38 on a more even platform with the KL6:
At 33 mm, the chopped 38 works well with the 5W Luxeon, after lifting it up .015" to alleviate the center null.
Although the reflector is not as deep as the KL6 as evidenced in the above photos, the spill beam is still quite impresive as one would hope with a 5W and the reflected beam is about the same in angle as that of the KL6. The chopped 38 has a sharper beam edge and I assume this is due to the KL6's reflector blending more with more of its reflected light merging into the spill area. The lux readings are likely indicative of this as well but since I know nothing of the relative flux of the two LED's hostd in these two lights, any evaluations are subject to assumptions. The lux readings at one meter that I got were 2030 for the KL6 and 2470 for the chopped 38. The M3 body hosting the KL2 mod has a two stage switch so it also measured a 240 lux on low level. The driver in the KL2 mod is a DB917 and the resistor in the tail switch is 30 ohm.
So after playing with this reflector, I have made some observations. First and most important to me, it works so it wasn't a waste of time and money {wiping the sweat from brow}. I don't know what alloy was used for this short run but it's the type of Al that is pretty gummy to machine. It's ultimately machnable to be sure but I have contacted my rep to the manufacturer to find out if any futute reflectors can be made from an easier to machine material. No word back yet. The reflective material used is very bright but prone to scratching and I need to learn how to get a cleaner "cut" at the edge of the reflective material as well as keep any of the "galling" Al burrs from encroaching into the reflective area. In both examples above, there are some scratches in the reflector at its edge which would certainly be nice to avoid!
I have mentioned to a few people that I think this reflector might be pretty cool in a mag host with a ring of 3 mm or 5 m LED's surrounding it and filling in the gap between head and reflector. I am completely ignorant of the Mag as host and don't welcome the learning curve of getting up to speed on it. /ubbthreads/images/graemlins/icon15.gif If time were to permit, I would like to visit maybe using George80's FatBoy with a pot on a LUX III in this reflector coupled with one of Dat2Zips constant current drivers on an array of 3 mm LED's for the task light aspect of the light. Could be a fun contest entry. /ubbthreads/images/graemlins/icon3.gif /ubbthreads/images/graemlins/smile.gif
One final comment on reflectors, I have also designed but not sampled a 25 mm reflector based on a different parabolic curve:
I am curious as heck as to what beam might result and I designed the reflector around the NX05 external dimensions in the sense that it could be chopped down with one solution being a drop in replacement for the current optic hosting lights. Being Al and having many flat steps for chucking in a lathe, this is my idea of a "chop to fit" reflector for modding use. I designed this reflector prior to two significant pieces of information that I now possess. One is the machinabiity of the Al used but it is very likely that this can be overcome but I am still waiting on word. The second consideration is the release of the so17xa which certainly does a wonderful job for its size! /ubbthreads/images/graemlins/thumbsup.gif I have no idea if my design would come close to parity with the so17xa or if it might even provide an other viable alternative. There are two things I do know for sure. 1) light would come out the front end efficiently but shaped n a beam that might be laughable. 2/) it could cost me a fair chunk of change to find out unless the manufacturer is wiling to cut me some slack on a small and affordable first article test; predicated on the promise to commit to a couple thousand dollar order if the FA is acceptable. I am currently pursuing #2. In fact many might propose I have done #2 with this post! /ubbthreads/images/graemlins/knight.gif /ubbthreads/images/graemlins/blush.gif
I designed a 38 mm diameter reflector based on the parabolic formula I am usng in my newest PR cloned reflector ( All credit and no blame go to Pelican and specifically a real gent who works there for allowing me "inside" back with the start of the PR series). Anyway, I have made one head in anticipation of getting a small and expensive prototype run of these reflectors done for evaluation and play. This built to suit host is shown below next to a 27 mm PR (I should probably start calling it a McR-27 since it is based on the PR but made for me off my own dwg) :
Well with the new reflector, I wanted to see how well it lent itself to being chopped and fitted to other hosts. My next experiment was to see how it would do in ArcMania's SF3 which sports a 30 mm optic that just doesn't float my boat. I chopped one of these down considerably to the 30 mm OD:
The results are very satisfactory. I should back up a bit and mention that the 38 mm when compared to a McR-27 gives a slightly tighter beam and on the same LED source (DB917) yielded a 4800+ lux at one meter in comparison to the 2400 lux from the 27. I believe it is safe to assume that as the 38 gets peared down towards the 27, both the beam and lux will approach that of the 27; it's the same reflective surface after all. So anyway, in the ArcMania SF-3, the beam is tighter and presumably brighter than a 27 mm host would be. I like seeing the head filed to capacity with a light engine and not the white frame of the 30 mm optic.
I wanted to see how this 38 would act on a 5W and instead of making a 5W ES module for the 38 proto head, I decided to get some more "chopping" experience as well as use a dead KL 2 that PK had given me. This would also give me a chance to compare the 38 on a more even platform with the KL6:
At 33 mm, the chopped 38 works well with the 5W Luxeon, after lifting it up .015" to alleviate the center null.
Although the reflector is not as deep as the KL6 as evidenced in the above photos, the spill beam is still quite impresive as one would hope with a 5W and the reflected beam is about the same in angle as that of the KL6. The chopped 38 has a sharper beam edge and I assume this is due to the KL6's reflector blending more with more of its reflected light merging into the spill area. The lux readings are likely indicative of this as well but since I know nothing of the relative flux of the two LED's hostd in these two lights, any evaluations are subject to assumptions. The lux readings at one meter that I got were 2030 for the KL6 and 2470 for the chopped 38. The M3 body hosting the KL2 mod has a two stage switch so it also measured a 240 lux on low level. The driver in the KL2 mod is a DB917 and the resistor in the tail switch is 30 ohm.
So after playing with this reflector, I have made some observations. First and most important to me, it works so it wasn't a waste of time and money {wiping the sweat from brow}. I don't know what alloy was used for this short run but it's the type of Al that is pretty gummy to machine. It's ultimately machnable to be sure but I have contacted my rep to the manufacturer to find out if any futute reflectors can be made from an easier to machine material. No word back yet. The reflective material used is very bright but prone to scratching and I need to learn how to get a cleaner "cut" at the edge of the reflective material as well as keep any of the "galling" Al burrs from encroaching into the reflective area. In both examples above, there are some scratches in the reflector at its edge which would certainly be nice to avoid!
I have mentioned to a few people that I think this reflector might be pretty cool in a mag host with a ring of 3 mm or 5 m LED's surrounding it and filling in the gap between head and reflector. I am completely ignorant of the Mag as host and don't welcome the learning curve of getting up to speed on it. /ubbthreads/images/graemlins/icon15.gif If time were to permit, I would like to visit maybe using George80's FatBoy with a pot on a LUX III in this reflector coupled with one of Dat2Zips constant current drivers on an array of 3 mm LED's for the task light aspect of the light. Could be a fun contest entry. /ubbthreads/images/graemlins/icon3.gif /ubbthreads/images/graemlins/smile.gif
One final comment on reflectors, I have also designed but not sampled a 25 mm reflector based on a different parabolic curve:
I am curious as heck as to what beam might result and I designed the reflector around the NX05 external dimensions in the sense that it could be chopped down with one solution being a drop in replacement for the current optic hosting lights. Being Al and having many flat steps for chucking in a lathe, this is my idea of a "chop to fit" reflector for modding use. I designed this reflector prior to two significant pieces of information that I now possess. One is the machinabiity of the Al used but it is very likely that this can be overcome but I am still waiting on word. The second consideration is the release of the so17xa which certainly does a wonderful job for its size! /ubbthreads/images/graemlins/thumbsup.gif I have no idea if my design would come close to parity with the so17xa or if it might even provide an other viable alternative. There are two things I do know for sure. 1) light would come out the front end efficiently but shaped n a beam that might be laughable. 2/) it could cost me a fair chunk of change to find out unless the manufacturer is wiling to cut me some slack on a small and affordable first article test; predicated on the promise to commit to a couple thousand dollar order if the FA is acceptable. I am currently pursuing #2. In fact many might propose I have done #2 with this post! /ubbthreads/images/graemlins/knight.gif /ubbthreads/images/graemlins/blush.gif
