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Thread: Adjustable Heatsink

  1. #1
    Flashaholic
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    Default Adjustable Heatsink

    I was asked to help a friend move more heat from his 5 watt "D" cell mod with a "push in" battery tube heatsink and came up with this heatsink.
    It threads into the mag's head just like the battery tube and by threading in or out will accomodate the SO 27 and SO 20 reflectors and the 30mm optic Elektrolumens sells and with a thicker lens o-ring (included) will allow using the SO17 reflector and NX05 and Fraen low profile (narrow beam) optics. (And maybe others that I don't own) Screwing the battery tube against the bottom of the sink locks it in the desired position and if you sand the annodize off the end of the battery tube, you will create a strong path to ground through the sink. The sink disk is about 3/8" thick 6061 aluminum and 1.535 in diameter threaded 20 tpi as is the battery tube. It uses my PR base connection for ease in changing hosts
    I include some thermocote heatsink grease for the threads and the thicker o-ring mentioned for using the smaller optics and reflectors. The LED shown in the picture is not included.
    The price is $16.00 shipped in the US. Cash Paypal only, please! Please PM me for international rates. I have 5 on hand and will make more if you want them!
    Thanks and Happy Moddering! [image][/image]

  2. #2
    Flashaholic* Icarus's Avatar
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    Default Re: Adjustable Heatsink

    Very nice. Brilliant idea! [img]/ubbthreads/images/graemlins/clap.gif[/img] [img]/ubbthreads/images/graemlins/happy14.gif[/img]

  3. #3
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    Default Re: Adjustable Heatsink

    I'll take one

  4. #4
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    Default Re: Adjustable Heatsink

    I would want one if it could be used with the 52mm reflector.

  5. #5
    *Flashaholic* IsaacHayes's Avatar
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    Default Re: Adjustable Heatsink

    I wonder if this would work to raise the emitter high enough into a 50mm Carlco mirror lens optic that people have wanted to mod...

  6. #6
    Enlightened
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    Default Re: Adjustable Heatsink

    Could you pop holes in it for a 3 star mod? Not that this isn't an excellent idea as it is, but with all the sinking, it just begs to have 3 stars on it.

    Larry

  7. #7
    Flashaholic* modamag's Avatar
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    Default Re: Adjustable Heatsink

    Nice work b2eze.
    Will this work with Mag reflector?

  8. #8
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    Default Re: Adjustable Heatsink

    [img]/ubbthreads/images/graemlins/paypal.gif[/img]

  9. #9
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    Default Re: Adjustable Heatsink

    Ah, shucks... thanks Icarus! PMs answered to cgpeanut and BC0311.
    Imcmann, there is not enough room to mount 3 stars on this sink, but I'm working on one that will allow 3 3 watt emitters to use the SO20, SO17, NX05, and Fraen Low profile (narrow beam).... It needs to be a little thicker than the star sink.
    Scrudinc, IsaacHayes... I truly can't say whether it will work with those reflectors....
    Modamag, I really doubt it will work with a cut down stock mag reflector, but I can't say for sure having never tried cutting one down, but this sink holds the base of the star 3/8" above the end of the battery tube and most of the stock reflector mods I've seen use a sink pressed into or resting atop the battery tube which, I'd guess would put the LED at most 1/8" above... There is very little space available in the Mag head to play with and still leave the o-rings covered to provide water resistance....

  10. #10
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    Default Re: Adjustable Heatsink

    Thanks cgpeanut... your sink will be on its way in the morning.
    Anybody know the height of the Carlco mirror lens? Sounds really interesting....

  11. #11

    Default Re: Adjustable Heatsink

    BRILLIANT!!!

  12. #12
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    Default Re: Adjustable Heatsink

    MR Bulk....Thank you! You've made my day! [img]/ubbthreads/images/graemlins/smile.gif[/img]

  13. #13
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    Default Re: Adjustable Heatsink

    Bc0311... your sink went out this morning too!
    Seemed to me the "v" shape of the screw threads meant at least twice the surface area for heat transfer as a simple "face to face" contact... the idea that different optics/ emitters could fit with one sink was an after thought.

  14. #14

    Default Re: Adjustable Heatsink

    Thank You, Wilson! [img]/ubbthreads/images/graemlins/grin.gif[/img]

    I thought this would be something Britt would want and seeing what Charlie said confirmed it for me.

    Cathi J.

  15. #15
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    Default Re: Adjustable Heatsink

    I'm STILL walking on air! MR Bulk's creations are legendary !

  16. #16
    *Flashaholic* KevinL's Avatar
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    Default Re: Adjustable Heatsink

    [img]/ubbthreads/images/graemlins/ooo.gif[/img] [img]/ubbthreads/images/graemlins/huh.gif[/img]

    Sweet heatsink - b2eze is the Master of the Dropin Mag Conversion.. and a PROPER conversion with real heatsinking (to flashaholic standards) too! Not only that, there is still adequate room for a small resistor or two, thus solving the "I want a drop in and I have everything BUT a 3-cell Mag" problem - resistor it up for 4D. SO20XA - now we're talking - my favorite reflector.

    Would it be possible to do one for C-sized Mags too? Just asking.

    PS: Isn't this the equivalent of the Light Engine concept for the Alephs, now brought over to the Mag world? Royal Blue one day, cyan the next, green the day after, and white for those days when you can't afford to play.

    I'm interested in one of the sinks - it solved the problem of "dang I'm gonna have to buy another light just to house a particular drop-in". My Mag85 can now double as a LED light [img]/ubbthreads/images/graemlins/grin.gif[/img]

  17. #17
    *Flashaholic* IsaacHayes's Avatar
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    Default Re: Adjustable Heatsink

    b2eze & Scudinc: If you used an emitter instead of a star, and there was enough room in the head for the stock mag reflector to fit, it can focus to the tightest. I have done this with flat heatsinks in the barrel tube. You must sand the back of the reflector after you cut it to remove the thickness of the plastic until it's close to sanding through to the chromed part. But don't enlarge it or sand into it. I have done this on both 3W & 5W setups and can focus a little past the tighest focus doing this so I know it works [img]/ubbthreads/images/graemlins/wink.gif[/img] This is how my luxIII S2J-Cyan is setup, on a 1/4" HS in the barrel.

    The mirror lens is pretty neat, I don't have any specs on it but I'm sure they are out there... I just know it's a 2 degree beam!

  18. #18
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    Default Re: Adjustable Heatsink

    Issac, I'm going to have to cut a mag reflector and try it to see! How far did you screw your battery tube into the head using the reflector? Is the battery tube o-ring covered?
    I was told the Carlco is only 9.1 mm high! I know nothing other than that about them, but I do know the concept of mirror or "cat" lens from my 35mm camera days (BD... before digital!)

    Kevin, Flattery will get you anywhere! I think I can do this for the new style "C" mags, so you can run the SO 20 as well as shorter optics and reflectors, but you would probably lose a lot of heatsinking since the sink would need to be raised from the head's ledge for the smaller reflectors and optics and the distance to the battery tube where the heat would be dispersed would increase. I doubt the loss of sinking would be worth the convenience. But if you want a sink for just the SO20 with the added sinking of threading into the battery tube as well as sinking through the ledge, I can do that with an additional 1/4" of threaded sink. Let me build one first, before I commit! Are you interested in single star or emitters?

  19. #19

    Default Re: Adjustable Heatsink

    Hey b2eze,

    The kudos are all yours, man. And if you could machine them with a slight "pedestal" on the emitter side I'd like to buy some. This would allow for easy use of the original Magflector, plus I have some new emitters that are not seeing use, just sitting around, since I switched over to Stars for current projects. Or do what Isaac said, or else one could even remove about 6-7mm (if I remember correctly?) from the bottom of the Mag's reflector to use your heatsink as-is with a Star, but I just prefer the pedestal route myself. Again, thanks for making something for the - hole-y Maglite...[img]/ubbthreads/images/graemlins/yellowlaugh.gif[/img]

  20. #20
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    Default Re: Adjustable Heatsink

    Yup, I've got a bunch of virgin mag reflectors left from 3 X 3 mods over the past year, I'm gonna cut some up! I'll let everybody know if they work with the threaded sink. If so, we'll find a way to make emitters work.... after all. if you've got a star, you've got an emitter. They're easy to pop off!
    MR B, you may not remember, but you turned me on to a Q3 star with a bubble in it a while back.... I had never seen such a thing and I still have it. Almost put it in a Arc LS, almost put it in a L1, almost put it in a KL1... But I like the bubble as much as the light!
    You've got a sink with your name on it... just gotta find the right format!

  21. #21
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    Default Re: Adjustable Heatsink

    Sorry ya'll.. Near as I can tell, this sink is useless with a cut mag reflector in a "D" mag. There is just not enough room in the head to put the emitter at the right height and leave thread in the head. What I would end up with would be a hot lips or o sink, both fine products! When I get more time to play, I want to make one up for "C" mags and try it there. Can someone point me to a post that will better educate me on the fine points of mag reflector filleting. I cut the cam end to the step on the inside... was that far enough? [img]/ubbthreads/images/graemlins/confused.gif[/img]

  22. #22
    *Flashaholic* IsaacHayes's Avatar
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    Default Re: Adjustable Heatsink

    b2eze, not sure how far. My setup is flat HS flush with the body tube, emitter on top of that, then head screwed on. Your're right your setup probably won't work too well for that. But for multiple emitters and using 20mm reflectors in a Mag D head this probably allows better heatsinking as you can have a thicker HS.

    I still want to see someone mod a 50mm optic into a mag!! with beamshots of course... [img]/ubbthreads/images/graemlins/smile.gif[/img]

    As far as cutting the mag reflector, here is what I do. I get a hack saw and cut around the cam leaving about 1mm extra, so I don't cut into the actual reflector. I will cut until I'm almost through (look inside the cam, you can see it turn white when you're about through), then go back with a razor blade and use that to finish seperating it, as a razor blade makes much a smaller cut than the wide hax-saw blade.

    Then clean it up with the razor blade around it. You should have cut off the cam and left all of the shiny part. If you don't have a pedistal heatsink and want optimal focus from an emitter on a flat HS, then take sandpaper on a flat surface and rub the backside of the reflector back and forth until you have sanded down the thickness of the plastic to where it is very thin, but not yet through to the reflective part. You're just thinning the plastic. This allows it to rest further down below the emitter. Doing this will even let you focus past the tightest point and it will widen out again, so I know this works for getting the best focus and you don't need to go further. I have done this on both 5W emitters, and 3W emitters. Should work for 1W as well because it's the same as 3W die size. Red-orange-amber I think will work too even with out sanding but I have not tried it this way because I had to raise the emitter on my 2C mag with a pedistal because it's and older mag and the head didn't screw down far enough to get the reflector close to it.

    I don't know about the new 3W red-orange-amber ones. I would assume it's possible with a flat heatsink too.

    When getting the dust out of a cut reflector, compressed air works good. If you have sanded the reflector, the finner the shavings of plastic from finer sandpaper, the harder they are to get rid of. Use high pressure air compressor. Don't touch the reflector! I've heard some have used water with success but only do that after air dusting, and getting rid of water spots is sometimes a problem.

    Hope this helps, it's a lot of text b/c that's all I know!

  23. #23
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    Default Re: Adjustable Heatsink

    Thanks mucho, Isaac! I'm going to have to cut my reflector a bit more, it seems! I'm curious whether a star will work with the stock reflector.... modified. I was pm'ed by someone else who wants to try the star route and I built him this sink for the barrel tube.... and one for me too! [image]http://
    [/image] [image]http://[/image] I plugged the hole with a slug of copper for a little more heat fransfer instead of the usual aluminum. What do you think?

  24. #24
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    Default Re: Adjustable Heatsink

    I love it. [img]/ubbthreads/images/graemlins/wink.gif[/img]

  25. #25
    *Flashaholic* KevinL's Avatar
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    Default Re: Adjustable Heatsink

    The center pedestal in the Hotlips/O-Sink raises the emitter to the correct height inside the reflector, since you cannot focus very well once you chop off the cam. It fits nicely into the reflector opening, I can imagine this would be hard to do with stars because the MCPCB of the star would prevent it from going into the reflector.

    The way to chop it off (you remove the reflector from the head first [img]/ubbthreads/images/graemlins/wink.gif[/img])


    Besides, I find the IMS reflectors offer many of the benefits plus a smoother beam with less artifacts than the stock Mag reflector. Retaining the use of the stock reflector is convenient and cost-effective, but suffers from many of the same drawbacks - focus changes with distance. The IMS reflectors are prefocused at any distance and with a SO27XA you can get some serious throw (think Lionheart throw).

  26. #26
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    Default Re: Adjustable Heatsink

    Have you put any more thought/work toward one of these for emitters?

  27. #27
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    Default Re: Adjustable Heatsink

    Ah jeeze!!!! 1idjack! Belated PM sent. I musta been sleeping!

  28. #28
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    Default Re: Adjustable Heatsink

    AH jeez 1idjack...... Belated PM sent to you.... I musta been sleeping!(or hibernating!!!!) 1 emitter will work fine on the copper slug sink shown above if glued down. 3 will fit with so20's but I need to make a plastic template to simplify placing the emitters for gluing. Soon, I promise.... sooner if ya'll pester me for it! Please PM me if you're interested!

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