Author Topic: Led Star Swap pictorial for the newer folks. Lotsa pictures!  (Read 8347 times)

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Offline 3rd_shift

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Led Star Swap pictorial for the newer folks. Lotsa pictures!
« on: February 16, 2008, 05:34:05 PM »
This is something I have been meaning to do for a while now and finally got around to it. ;)
This pictorial will give you the knowledge on how to do a simple led star swap in your older Luxeon1, or Luxeon3 flashlights up to..
 a much newer, efficient and more powerful Seuol Semiconductor led star. :)

Let's get started with some tools and equipment.


The flashlight featured for this is a Nuwai TN115x with a 2 stage switch.
It's head came right off with no issues.
However, there is a retainer ring in there that needs to be unscrewed out before we can go further.
I used "needlenosed" needlenose pliers. Use anything similar that you like for this purpose.


Now we find 2 small black screw that are holding the star in.
Carefully unscrew those out with a proper fitting screwdriver, or screwdriver bit.


Done. :)
Now unsolder and lift up the wires from the star with a "pencil" type soldering iron.


Got it, but wait a minute...
Check this out, the wire on the (-) pad was not a wire.
It was a (-) ground tab.....clever. ;)


Here's the new led.
A top quality performing and top quality looking led. :)
We are now ready to do the reverse of the dissassembly.
We are halfway there!


Put some rosin flux on the ground plate's tab.


Since the led (-) is coming from it's backside, we want a good electrical contact.
Bulb, or contact grease is used this time instead of heatsink thermal compound.
I have had good luck with contact grease just as much as thermal grease so far in the past.


Slide on the (-) contact plate and center it so it won't block the star mounting screws.


Solder the (-) contact tab to a (-) pad on the star.


Put some more contact grease in where the star is going.


Put some rosin flux on the (+) wire.


Put the light in some kind of a vise, or firm holder as you may need two hands.
One to hold down the (+) wire while soldering it at the same time.
Make it neat.


It should look this good, or better for best results.


Let's put those screws back in.
If they were difficult to remove, use a magnetic screwdriver and lube the screws before putting them back in.


Done, but make sure that emitter and star are centered, or the light will have a crappy beam.
Loosen the screws and center the led best you can and then carefully retighten them.


Put the retainer ring back in.


Done. :) But not too tightly.


Put in a 3.7 volt rechargeable 17670 battery, or 2 cr123 batteries and give it a go with the head screwed back on.
And..... Voila! We now finaly have a really white light source!! LOL!!


Here it is with a 17670 sized 3.7 volt lithium ion recharge-able battery with a (+) button on it.


Here it is on low mode.
About 18-19 milliamps.
This is the same power level that properly driven T5 style leds are driven at.


On high mode at 340 milliamps.
This is only 10 milliamps short of what the manufacturer of the led says it's designed to be driven at.
Certainly no issues here. ;)


Low mode with 2 cr123 disposable batteries at 6 volts total this time.
Almost 50 milliamps this time for some reason, quite a jump from 18ma.


High mode at 830 milliamps.
Still not too bad as long as one does not expect the full rated 100,00 hours from the led.
But hey, this is a flashlight! Right? :)

plantruler@hotmail.com
is my email and paypal address. :)
Observe and report what you saw with a good flashlight. ;)

Offline LeDfLaShEr

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Re: Led Star Swap pictorial for the newer folks. Lotsa pictures!
« Reply #1 on: February 17, 2008, 04:04:08 PM »
I've always been curious if the Seoul star was the same height as a Luxeon. I'm really wanting to work some magic on a Lioncub, but wasn't so sure if it would be a straight across switch.

Offline Geologist

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Re: Led Star Swap pictorial for the newer folks. Lotsa pictures!
« Reply #2 on: February 17, 2008, 04:26:50 PM »
3rd Shift - as always - excellent stuff!

Gonna call you the STICKY King!
Dragon, Ti, and Classic Chammies, Blk, Bare, & Brass LCs, Blk & Bare LHs, X990, Rayzorlite, The Torch, Mag85, MagGH24, SF C3, C2, 6P, G2, & Winelights, Peak Caribbean, Pacific, McKinnleys, + more , Exolion Ti, Orb Raw NS, SS Gatlight, Eternalights, Nuwai QIII, Inova X5THAs, X1, ARCs, + more?

Offline arewethereyetdad

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Re: Led Star Swap pictorial for the newer folks. Lotsa pictures!
« Reply #3 on: February 17, 2008, 10:11:35 PM »
3rd Shift - as always - excellent stuff!

Gonna call you the STICKY King!

+1.  Outstanding stuff.  Definitely sticky material for those of us who are completely clueless as to how to do this.   :thumbup:  :thumbup:

Offline 3rd_shift

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Re: Led Star Swap pictorial for the newer folks. Lotsa pictures!
« Reply #4 on: February 18, 2008, 01:03:42 AM »
I've always been curious if the Seoul star was the same height as a Luxeon. I'm really wanting to work some magic on a Lioncub, but wasn't so sure if it would be a straight across switch.

It almost is.
I have already "Seouled" my Lioncub with good results with a USVOL binned SSC P4 led. :)
It must end with an ****L in order to work right with a Lionheart, or a Lioncub.
That last letter has to do with the led's forward voltage requirement.
Anything lower means that a slight, .5 ohm resistor is needed to keep the led from getting fried.

Good luck. :)
plantruler@hotmail.com
is my email and paypal address. :)
Observe and report what you saw with a good flashlight. ;)