DIy 700 lumen batteries inside light

IIRC some people have used it for sealing bastid batteries but not used myself.

I have a big tin of the stuff and dip all the batteries I send out with a Troutelight good stuff it is .

but not cheap to just buy for one battery .

Hi Lipseal …. Point your light up in the sky southward ….. see if I can see it from Crosby!

If you’re down anywhere near this way after dark … or someplace in between, let me know … I could compare it with my ancient halogens while I wait for Trouties next batch of Led’s to come in.

Got itchy fingers here just AAA’ng ali to drivers and drilling the odd hole …. must see lumens!

Don’t know when I will be able to have a go at one of these but really fancy it. I was wondering about improving heat dissipation so started Googling ally extrusions. Found this – http://www.birminghamaluminium.com/heatsinks_home.php

Just thought I’d share in case anyone is interested. You can also get simple ally radiant/heatsink from Maplin too. Thought if you used thermal paste between radiant and case and long screws through the radiant in to the internal heatsink you would get transfer up to the radiant. May be overkill but I’m Capt. Paranoid plus may add that pro look to the box.

Trout . Can i be put on the new list for a kit please. Had a go at making one before but this one seems to be alot better than my attempt.

Blackcat. i would also need a driver please (not to fussed about the other bits if you dont have them).

BH I should be able to pop down to Crosby on Thursday night, let me know if this is ok and email.

I’ve recompiled the possible-Round-2 list from the past few pages, its a bit confusing, dunno how trout and bct keep up. If I’ve missed you or you shouldn’t be in it update the list and repost.

runswithscissors LED kit
bobblehat 4 * 20mm xp-g
john_walker74 LEDs & Driver
bigjim LED kit + driver kit
mau00149 led kit + driver kit
norcbot led kit + driver kit
landy813 – driver

by jingo it actually works!

just need some silicone to seal it up and stop the cones rattling (mis-aligned one of the angle mounts ever so slightly). no pics of inside as, quite frankly, my soldering is an embarrasment – but it works! i`ll post a pic of the finished article in a bit.

just need to sort the mount and i`ll be off.

it appears quite a tight beam so we’ll have to reserve judgement till i’ve used it in anger but its ‘bloody bright'(tm) – i can floodlight my pumptrack (about 100ft away at the bottom of my garden) from the balcony no problem.

big cheers to trout and BCT. jobs a goodun!

Update No.1……
runswithscissors LED kit + Driver kit
bobblehat 4 * 20mm xp-g
john_walker74 LEDs & Driver
bigjim LED kit + driver kit
mau00149 led kit + driver kit
norcbot led kit + driver kit
landy813 – driver

My 1st attempt actually works! Off to the woods to try it out tonight.

tee hee. could cut the case down a bit and probably will at some stage but its not heavy as it is. put a tamiya connector onto BCT`s power cable but didnt use the socket – cable is fixed to the head unit so detach the battery to charge.

all made using regular tools and good old fashioned bodging. the hardest bit was getting hte angle drilled in the right place to mount it to the box as i have nothing to hold it in place as you drill through

Update No.2……
runswithscissors LED kit + Driver kit
bobblehat 4 * 20mm xp-g
john_walker74 LEDs & Driver
bigjim LED kit + driver kit
mau00149 led kit + driver kit
norcbot led kit + driver kit
landy813 – driver
Clobber LED kit + driver kit + 2*20mm xp-g (please)

Looking at this, one thing that comes to mind is, would it be a good idea to chamfer the edges around the front panel holes/reflector opening, as there are a good few mm of overlap which might cut some beam spread?

List update … thanks Troutie

runswithscissors LED kit + Driver kit
bobblehat 4 * 20mm xp-g + 2 pieces of lexan please!
john_walker74 LEDs & Driver
bigjim LED kit + driver kit
mau00149 led kit + driver kit
norcbot led kit + driver kit
landy813 – driver
Clobber LED kit + driver kit + 2*20mm xp-g (please)

Looking at this, one thing that comes to mind is, would it be a good idea to chamfer the edges around the front panel holes/reflector opening, as there are a good few mm of overlap which might cut some beam spread?

Just a bit of parallax, holes are 20mm for a 19mm reflector.

Nice light VH, any ideas how you will seal battery?

List update (my original request was missed off!)

Jazid – xpg LED Kit (incl. lexan + angle) + Driver Kit (3way + 2way)
runswithscissors LED kit + Driver kit
bobblehat 4 * 20mm xp-g + 2 pieces of lexan please!
john_walker74 LEDs & Driver
bigjim LED kit + driver kit
mau00149 led kit + driver kit
norcbot led kit + driver kit
landy813 – driver
Clobber LED kit + driver kit + 2*20mm xp-g (please)

Any idea where we can source a micro pot. (as in http://forums.mtbr.com/showthread.php?p=7076204 )

not sure LS. my old solution was putting it in a waterbottle and seal the cable entry

however my new frame doesnt have a bootle mount so i`ve been taping the batt direct to the toptube. i generally dont ride if its sheeting it down so i was considering judicious use of a food bag and more tape for sealing on damp evenings

alternatively i`m sure there must be some tupperware in the world that is the right size! not very pro i know but then its dark when you use it!.

Good stuff fellas hopefully be a few more working ones along soon .

Thanks for updating the list too .

Just been making a jig to drill the stars so they may come predrilled for the reflector depending on spare time available .

I’d like a kit too please but just wanted to check what kit I actaully need – I want to make the whole light – it take it thats the led kit and driver kit?

Damo’s (missing) update to the list

Jazid – xpg LED Kit (incl. lexan + angle) + Driver Kit (3way + 2way)
runswithscissors LED kit + Driver kit
bobblehat 4 * 20mm xp-g + 2 pieces of lexan please!
john_walker74 LEDs & Driver
bigjim LED kit + driver kit
mau00149 led kit + driver kit
norcbot led kit + driver kit
landy813 – driver
Clobber LED kit + driver kit + 2*20mm xp-g (please)
Damo2576 – LED & Driver Kit)

Damo2576, this thread is now over 500 posts long and there is a lot of detail, however very rougly you’ll also need;
A Hammond metal case (from maplins http://www.maplin.co.uk/Module.aspx?ModuleNo=33690 .e.g. N82AL) – Trout’s L angle ali strip is cut for this case.
Battery pack (e.g. 8xAA battery holder e.g. RK44X + 8 rechargable AA’s)
Thermal conductive compund for transferring heat away from LED ( e.g.Artic Silver or own homemade epoxy)
Various 2/3/4mm self tapping screws (the ali case is soft enough for self tappers or make your own thread with a tap/die set)
Fibre washers to place between the screw head and led

A Hammond metal case (from maplins http://www.maplin.co.uk/Module.aspx?ModuleNo=33690 .e.g. N82AL) –

wonder if the plastic or alu ended version is easier?

the metal ended one you dont need to cut for the lexan/perspex as you use the metal plate as a guide and replace it.

the plastic ended you’ll need to cut holes as per CK’s light. i didn’t have the kit to do this nicely so went for the metal plate option. it doesnt look as smart but its about what you have the tools to do.

Another Update:

Jazid – xpg LED Kit (incl. lexan + angle) + Driver Kit (3way + 2way)
runswithscissors LED kit + Driver kit
bobblehat 4 * 20mm xp-g + 2 pieces of lexan please!
john_walker74 LEDs & Driver
bigjim LED kit + driver kit
mau00149 led kit + driver kit
norcbot led kit + driver kit
landy813 – driver
Clobber, 4xLED kit + 4xDriver kit + 2*20mm xp-g (these are for friends so I’ll make sure there is a profit for you Troutie!)
Damo2576 – LED & Driver Kit)

@jazid – thanks

I think I’ll add a bit extra so trout and bct are at least getting some money for their time, we must be a right pain in the proverbials…

Does anyone order from farnell?

BCT/Trout/Smudge – are these trimmers any good as a replacement for the resistors to allow control of the light levels?
http://uk.farnell.com/jsp/displayProduct.jsp?sku=9353461&CMP=e-2072-00001000

No Good for controling a light as they are limited to 25 sweeps so will wear out fast if used constantly .

you could go all posh and use the Maxflex and Bflex drivers but they are $35 plus shipping from the USA.

Troutie said …. Good stuff fellas hopefully be a few more working ones along soon .

Thanks for updating the list too .

Just been making a jig to drill the stars so they may come predrilled for the reflector depending on spare time available.

Bl00dy brilliant Troutie …. pre-drilled stars … absolutely outstanding! I was ummming and arring over drilling or cutting off the reflector pins …. if you can do that I’ll be doing cartwheels (not a pretty sight … probably!)

Also, Chris, I’ve got a 300mm+ length of 20mm x 10mm x 1.5mm U channel going spare, if you’d like it FOC to distribute … could get 6 Led plates out of it. Let me know … if not, I’ll cut and donate it UK builders.

Pots – you really need a log potentiometer to get the best dimming results. Most presets are only available as linear track. You also need the biggest value you can get as it limits the maximum output – unless you use a switch to cut it out of the circuit.

Jazid – Just placed a Farnell order today and am likely to be placing another in the next week or so. I seem to recall Farnell did an IP65 potentiometer when I was looking for one a few years back but they were fairly expensive. Would avoid the need for a switch though.

These parts from Farnell may be of interest, either as an additional external heatsink (first one) or as alternatives to the angle, although some machining will still be needed:

1773307
1773372
4621323

By the way, Farnell also stock the Regina – I’ve just bought 10 at 92p each plus VAT – they only had 25 left when I last checked though! They were awaiting delivery last time I checked so either they didn’t get many in or they have flown off the shelves…

By the way Troutie, please put me down for two XPGs if you are doing another order – I will be ordering myself from Cutters sometime soon for the Lumicycle project but if you are ordering before then I’ll just take two of yours.

Bct, thanks for the reply. I was after a preset pot so I could adjust it internally and then screw the light back together, which gives me a way of setting the 2 positions <100pct on my 3 way switch beforehand to suit the ride and desired runtime. Any suggestion on the type and rating of a suitable pot?

Thanks for the offer Bob and if it will do the job the chop it and donate it to the ones on here .

My first lot of leds have now become the second due to delays in OZ.

what happened is I have a large order coming in for my Liberators so added on 50 leds for the interest on this thread .
but suspected there would be a delay due to the lack of comms from over there.
so ordered 50 leds from Ledtech.de so as not to keep you all waiting
they came in very quick and that is history .

the first lot and my others have now made it to china and are in transit hopefully to me this week .
so I was gambleing on some more folks jumping on the ship to buy these leds too but wasnt too worried as they would come in handy for doing the Ayup-grades which seem to be a goer

Ledtech.de so as not to keep you all waiting
they came in very quick and that is history

Does that mean they are slow to deliver? I am so impatient and missed the boat last time that’s where I got my stuff from to do the build, fairly expensive too due to the small amount of stuff I got.

Are these any good more lumen’s for less current?

This appears to be a really interesting thread that i would love to read but i think it will take about 3 weeks.

Any chance of a condensed post of what the general gist of making one is etc etc?

Chris, did you get my email yesterday?

No all my dealing with LT have ben swift
Cutters have also been impecable but have seemed a little slack just lately .
and it seems they have been going through ISO accreditation and it has been taking up their time so future stuff should be quicker.

Will do Steven , have you got stock of the other resistor on board drivers or are you upgrading those too .

Jason yes just read it nothing in there to supprise but if you want to send it back I will have a look into it .

may be the non waterproof switch or connector .

Bland .condensed version .

its a killer light you can build yourself .
most of the detail is on the first pages and lots of helpfull folks on here to help out if you get stuck .

😆

CK, where did you get the 18650 holders from, home made ?

Are you charging them indidually as opposed to in series ?

Trout, just let me know when you want the money for the LEDs and I will paypal you. Could I update it to 2 kits though. Updated list below:

Another Update:

Jazid – xpg LED Kit (incl. lexan + angle) + Driver Kit (3way + 2way)
runswithscissors LED kit + Driver kit
bobblehat 4 * 20mm xp-g + 2 pieces of lexan please!
john_walker74 2* LEDs and bits & 2 * Driver
bigjim LED kit + driver kit
mau00149 led kit + driver kit
norcbot led kit + driver kit
landy813 – driver
Clobber, 4xLED kit + 4xDriver kit + 2*20mm xp-g (these are for friends so I’ll make sure there is a profit for you Troutie!)
Damo2576 – LED & Driver Kit)

Yet Another Update:

Jazid – xpg LED Kit (incl. lexan + angle) + Driver Kit (3way + 2way)
runswithscissors LED kit + Driver kit
bobblehat 4 * 20mm xp-g + 2 pieces of lexan please!
john_walker74 2* LEDs and bits & 2 * Driver
bigjim LED kit + driver kit
mau00149 led kit + driver kit
norcbot led kit + driver kit
landy813 – driver
Clobber, 4xLED kit + 4xDriver kit + 2*20mm xp-g (these are for friends so I’ll make sure there is a profit for you Troutie!)
Damo2576 – LED & Driver Kit)
Steelrider – LED kit + driver kit

fozzy

CK, where did you get the 18650 holders from, home made ?

Are you charging them indidually as opposed to in series ?

I was thinking of buying some of the 18650 holders from digikey. They are designed to be PCB mounted but they are a lot cheaper than getting the pnes from Luminousdiy in the US and I don’t have the tools to make my own. Looks like you can wire them up fairly easily though.

I think I’ll run this light from 4×18650, just because I already have the 18650 charger and so its a cheaper route than one of smudge’s batteries & charger (sorry smudge!). I’m also converting two MTE P7 torches to run off a 2×18650 battery pack so I was going to get some holders for that anyway. Might try and bodge 2 of the 2xholders into a series 4 or might just get the flat x4 one.

I guess in the spirit of things I should see if anyone else wants any of the digikey 18650 holders, digikey’s postage is £12 so its a pain when just getting a few quids worth of stuff. I don’t want to offer to order anything other than the battery holders as I can’t be *rsed posting anything like Hammond boxes or anything. Unless anyone knows any better alternatives?

Just been out for a blast in the woods to tryout my “Hamfist” light. it’s really really good, quite a narrow beam but was awesome as a helmet light and need to update my order as my buddie wants me to build him one now! Thanks for all the help from everyone on here esp. the parts suppliers…. 😆

so next update
Jazid – xpg LED Kit (incl. lexan + angle) + Driver Kit (3way + 2way)
runswithscissors 2x LED kit + Driver kit
bobblehat 4 * 20mm xp-g + 2 pieces of lexan please!
john_walker74 2* LEDs and bits & 2 * Driver
bigjim LED kit + driver kit
mau00149 led kit + driver kit
norcbot led kit + driver kit
landy813 – driver
Clobber, 4xLED kit + 4xDriver kit + 2*20mm xp-g (these are for friends so I’ll make sure there is a profit for you Troutie!)
Damo2576 – LED & Driver Kit)
Steelrider – LED kit + driver kit