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 Post subject: Revolver Mk IV.
PostPosted: Tue May 05, 2015 9:08 am 
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timid kitty

Joined: Sun Feb 22, 2015 11:06 pm
Posts: 33
I have built a number of lights in the past, going back many years to the days of lugging around a 7ah 12 volt motorcycle battery to power a 50 watt halogen.

Over the last few years I have got a bit more advanced, building high power custom led light rigs, which I documented on EB in the lights DIY forum. The last helmet rig was stupid bright, pumping out about 4k lumens, but the beam ended up being somewhat disappointing, so I've spent the last couple of years contemplating one last helmet rig.

It was finally time to start cutting some alloy, and I thought I'd show you good people here at HK my progress.
So here is my photo journal of current progress.


Attachments:
File comment: Roughing out the shape and machining the heat-sink.
IMG_3631.JPG
IMG_3631.JPG [ 155.23 KiB | Viewed 5404 times ]
File comment: Machining the grooves just for the look of the thing. The screw hole was drilled in the same fixture.
IMG_3669.JPG
IMG_3669.JPG [ 96.32 KiB | Viewed 5404 times ]
File comment: Mount machined out of a piece of acetal. The bolt is a simple allen head bolt that screws into the existing thread in the helmet for the visor adjustment.
IMG_3670.JPG
IMG_3670.JPG [ 79.88 KiB | Viewed 5404 times ]
File comment: Built in cable glands.
IMG_3676.JPG
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File comment: The mount uses an alloy core that screws into each light head. The thin acetal sleeves allow the light heads to be aligned nicely and provides good friction when tilting the lights up and down.
IMG_3680.JPG
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IMG_3681.JPG
IMG_3681.JPG [ 93.51 KiB | Viewed 5404 times ]
File comment: The inner acetal sleeve stops the allen head screw from coming out of the mount, so it won't get lost when off the helmet.
IMG_3683.JPG
IMG_3683.JPG [ 84.05 KiB | Viewed 5404 times ]

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 Post subject: Re: Revolver Mk IV.
PostPosted: Tue May 05, 2015 1:23 pm 
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pussy
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Joined: Tue Jan 15, 2013 5:23 am
Posts: 3762
Very cool! What kind of lenses/mirrors do you have in these?


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 Post subject: Re: Revolver Mk IV.
PostPosted: Tue May 05, 2015 1:35 pm 
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bad kitty!
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Joined: Tue Jan 15, 2013 11:22 am
Posts: 2290
And now you wanna tell me you can't make a watch case? :D


Magura :)

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 Post subject: Re: Revolver Mk IV.
PostPosted: Wed May 06, 2015 1:13 am 
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friendly kitty
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Joined: Mon Dec 29, 2014 10:56 pm
Posts: 351
Location: Grand Prairie, TX
Such nice machining.... I've always been jealous of the machined lights on EB. I am "stuck" living with rectangular tubing lights.... of course, I still get to ride at night, so I am not THAT jealous. :)


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 Post subject: Re: Revolver Mk IV.
PostPosted: Fri May 15, 2015 1:54 am 
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timid kitty

Joined: Sun Feb 22, 2015 11:06 pm
Posts: 33
Thanks for the comments guys.

I had tried to reply a couple of times, but each time the system has logged me out instead of letting me reply. I don't know why.

The leds, driver, and optics arrived this morning.
One each triple XPG-2 and XPE-2, cool white and warm white respectively. I would have preferred neutral while for both, but couldn't get it.


Attachments:
IMG_3701.JPG
IMG_3701.JPG [ 87.79 KiB | Viewed 5171 times ]
File comment: The watch is just to show scale.
IMG_3702.JPG
IMG_3702.JPG [ 98.77 KiB | Viewed 5171 times ]

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 Post subject: Re: Revolver Mk IV.
PostPosted: Fri May 15, 2015 10:51 pm 
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big hucker
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Joined: Wed Jan 16, 2013 7:32 pm
Posts: 3086
Location: Dallas, TX
Those enclosures are a work of art. I really need to find room in my garage for a small lathe...

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 Post subject: Re: Revolver Mk IV.
PostPosted: Thu May 21, 2015 10:51 am 
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timid kitty

Joined: Sun Feb 22, 2015 11:06 pm
Posts: 33
marpilli wrote:
Those enclosures are a work of art. I really need to find room in my garage for a small lathe...



Ah, but do you really need another obsession? Because buying the lathe is only going to be the beginning of your expenditure... There will always be a new attachment that you 'need'. Ask Magura. I'm sure he knows.

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 Post subject: Re: Revolver Mk IV.
PostPosted: Thu May 21, 2015 11:12 am 
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timid kitty

Joined: Sun Feb 22, 2015 11:06 pm
Posts: 33
I finally finished the last bit of machining last night.... heat-sinks for the driver boards. One each for my new helmet build, and for an update to my bar lights. Then it was time to give the light heads a quick polish on the buff before packing everything up and sending it off for anodizing. At that point I should have got on with some serious work, but instead I drilled down into the legs of the optics, and filled them with luminous powder... because, well why not?

Hopefully in about a week or so I will be able to finally build them up.


Attachments:
File comment: The B3Flex driver needs to be attached to a heat-sink where the outline is. This will be fixed using Arctic Aluminum adhesive.
IMG_3716.JPG
IMG_3716.JPG [ 89.25 KiB | Viewed 5088 times ]
File comment: Final polish.
IMG_3721.JPG
IMG_3721.JPG [ 97.88 KiB | Viewed 5088 times ]
File comment: Drilling the posts.
IMG_3718.JPG
IMG_3718.JPG [ 89.39 KiB | Viewed 5088 times ]
File comment: Filling the cavities with a really small funnel.
IMG_3719.JPG
IMG_3719.JPG [ 77.9 KiB | Viewed 5088 times ]
File comment: When the lights are turned off there should be a fairly subtle green glow in the lenses,.
IMG_3720.JPG
IMG_3720.JPG [ 121.13 KiB | Viewed 5088 times ]

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 Post subject: Re: Revolver Mk IV.
PostPosted: Sun May 24, 2015 1:36 am 
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pussy
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Very nice! Green glow - where does it come from, the lens material? My XXX glows quite a bit.


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 Post subject: Re: Revolver Mk IV.
PostPosted: Sun May 24, 2015 7:46 am 
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timid kitty

Joined: Sun Feb 22, 2015 11:06 pm
Posts: 33
The glow is from luminous powder inserted into the legs of the optics. I normally use it for restoring luminous watch hands. In the photo I have an optic sitting under a black light that I use for setting off UV glue I use for gluing in watch crystals. There was still a fair bit of spilled powder on the optic in that shot, but it should give quite a nice effect when they are mounted in the light heads. Like watch hands, the powder will absorb light while the lights are running, and then emit it for some time afterwards.

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 Post subject: Re: Revolver Mk IV.
PostPosted: Sat Jun 13, 2015 1:38 am 
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timid kitty

Joined: Sun Feb 22, 2015 11:06 pm
Posts: 33
Time for an update.

I finally got my new lights running.
In a last minute decision I got them dyed grey after anodizing. Initially when I opened the box from the anodizers I was a bit disappointed, as up close the finish has dark spots on it, but then I realized that they don't really stand out, and I got over it. I then had to wait about another week to receive the latest and greatest Cree XP-L Hi Intensity leds from Cutter Electronics in Australia. These leds are ridiculous, pumping out about 1000 lumens each, and there are 6 of them. They look strange because they have been de-domed to give more throw. The original domed versions have a higher lumen count, but won't fit under the XP series optics. I was one of the very first recipients of these new leds, and got them on direct to copper Noctigon pcbs.

I'll save the blow by blow account of wiring them up and go straight to the pictures:


Attachments:
IMG_3762.JPG
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IMG_3772.JPG
IMG_3772.JPG [ 149.82 KiB | Viewed 4776 times ]
IMG_3773.JPG
IMG_3773.JPG [ 120.79 KiB | Viewed 4776 times ]
IMG_3774.JPG
IMG_3774.JPG [ 87.97 KiB | Viewed 4776 times ]

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 Post subject: Re: Revolver Mk IV.
PostPosted: Sat Jun 13, 2015 1:54 am 
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timid kitty

Joined: Sun Feb 22, 2015 11:06 pm
Posts: 33
On the back of the helmet I used some polymorph (which I dyed black) and deans type connectors to make a junction between the helmet and the power lead. Polymorph is wonderful stuff. Also called "friendly plastic", you buy it in pellet form and then heat it up to over 65C. It can then be moulded into any shape you like, and when it cools, it hardens into a plastic very like nylon. The allows quick fitting and removal of the lights while still running the cables inside the helmet out of harm's way. At this point I have the driver board and mode switch down on my shoulder strap of my camelbak, but on my maiden ride I found this arrangement to be a massive pain. I will make up a new driver housing for the back of the helmet next week some time. It wouldn't be so bad, but I realized after the fact that it isn't good to connect the battery to the driver without the driver connected to the led. This rather stuffs up my whole reason for having the driver down off the helmet itself.

Finally, performance....... Well the back yard test was stunning..... but on the trail it was slightly underwhelming. It does put out a LOT of light, but unfortunately these Carclo optics don't seem able to focus the huge leds properly, so it lacks ultimate throw. I have found that on a helmet light, for my riding, and lot of throw with a decent center spot is crucial. So, since I still have the original leds I had bought, one each board of XP-G2s and XP-E2s, I am going to pull the lights apart and do some reflowing. I will remove two of the XP-Ls off each board, and replace them with one each XP-G2 and XPE-2. This should provide about 4.5 to 5k lumens overall, but with awesome throw and flood.

The really good news though, is that these tiny housings have absolutely no trouble shedding the heat generated by 3 amps worth of power going through them.... at least as long as I am moving.


Attachments:
IMG_3775.JPG
IMG_3775.JPG [ 83.41 KiB | Viewed 4775 times ]
IMG_3776.JPG
IMG_3776.JPG [ 78.65 KiB | Viewed 4775 times ]
IMG_3777.JPG
IMG_3777.JPG [ 84.04 KiB | Viewed 4775 times ]

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 Post subject: Re: Revolver Mk IV.
PostPosted: Sat Jun 13, 2015 3:44 am 
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timid kitty

Joined: Sun Feb 22, 2015 11:06 pm
Posts: 33
....Since they are lights I should probably show them working.


Attachments:
IMG_3779.JPG
IMG_3779.JPG [ 76.33 KiB | Viewed 4758 times ]

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 Post subject: Re: Revolver Mk IV.
PostPosted: Sun Jun 14, 2015 7:27 am 
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yappin' kitty

Joined: Wed Feb 18, 2015 11:20 pm
Posts: 826
That is a serious night-killer, US.

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 Post subject: Re: Revolver Mk IV.
PostPosted: Sun Jun 14, 2015 4:41 pm 
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pussy
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Great job, U. Take some pictures of the light in action.


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