Author Topic: DIY 700+ lumen SSC P7 3D Maglite modding, Lotsa pics!  (Read 32093 times)

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Offline 3rd_shift

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DIY 700+ lumen SSC P7 3D Maglite modding, Lotsa pics!
« on: April 05, 2008, 09:26:26 PM »
1st of all, here is the problem with a stock 3D Maglite.
Here it is pictured with a 60 watt outdoor lamp.

Ya kinda get the idea that current flashlight technology needs some help.

New led = another pictorial ;)
Seoul semiconductor has done it again with thier latest P7 led.

Let's break out some tools and have some fun!

Take off the head tailcap and dump out the batteries.


Take off the switch boot without tearing it up and use a 5/64ths allen wrench to loosen the switch assembly.


Use the same allen key hex wrench to loosen the bulb holder guts.


Dump those out.


Make the switch assembly look something like this.


Make the stock reflector look something like this nice and neat.
Go ahead and ream out about an additional 2 millimeters from it's apex to make that bigger for this large P7 led.


Heatsink makers; we have a little problem here.
None of these heatsinks are flat topped for this large led's slug.
The ideal heatsink would be flat topped and type3 annodized for electrical isolation.


I finally flat topped the h22a bare aluminum unit for this demonstration.
But we still need to electrically isolate this big and expensive led's (+) bottom from the light's (-) ground. :(


Cree to the rescue.
I cannibalized an obsolete P2 flux Cree XRE for it's ceramic base to use as a thermally conductive electrical isolator.
Remove and shave all the guts and cut the corner pass-through contacts off.



Mix up some 2 part arctic alumina.


Apply the rigged isolator to the heatsink and bullseye center it.


Do the same with the led on top of that.


Cut a couple of wires like this about 5 inches long.


Preflux the wires and the places where they are getting soldered to with rosin flux.


Wire these into the switch assembly like this nice and neat.


Re-install the switch assembly into the light.


Has the Arctic Alumina adhesive hardened yet?
Good, we have more work to do with that heatsink.
Drill 2 more holes carefully like this because the led is too big for the original ones.


Now we can wire up this led heatsink assembly.


Bend and squish the wires into the flashlight a little something like this.


Note:
The led has a pinhole in one of it's leads.
That is it's (-)

Guide the wires into the heatsink noting the led's polarity.
Apply heatsink grease to the heatsink and push it into the light.
It went right in this time. :)
Use a hollow pvc pipe and mallot if needed to drive it in fully without splatting the fragile led.


Bring the wires through like this a little more and preflux them with rosin flux.


Put the light in a gentle vise, or holder and use two hands to position and solder the wires into place.


Okay, load the batteries back in without the tailcap.
Push the switch to the "on" position and give it a go with a dc ampmeter.
Here it is with fresh alkalines at 1.72 amps, no problem here. ;)


Again with Nicad D cell batteries at about 2.3 amps.
Still no issues here either.


This is why the reflector's apex was reamed out bigger earlier.
The big led and it's "wider stance" wiring made this necessary.


Still, there never was any light hitting the removed part of the apex anyways.
No harm there.


Remember this?


Now watch this!


60 watt vanity light getting clobbered.


4 26 watt compact flouros at 1600 lumens each getting lit up a bit.


4x100 lumen quad UXOJ binned Luxeon3's totalling about 400 lumens getting owned.


Obsolete Luxeon5 WX1T pushed to near 200 lumens getting beaten bad in every way.


Call the Police or Security!
Stock Magcharger getting clobbered.


Happy modding!!

Edit:
Update:
I finally charged some nicad D cells fully and without thinking about it, pulled them from the charger, put them in the light, turned it on and.....
 WOW! 
Significantly brighter than when I took the beamshots earlier.   8)

Got the ampmeter and found 3.3 amps running through the light.   :-[

As for nimhs?
Let those rest 1st before using them in a direct drive light like this one.
« Last Edit: April 06, 2008, 12:47:50 PM by 3rd_shift »
plantruler@hotmail.com
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Observe and report what you saw with a good flashlight. ;)

Offline glockboy

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Re: DIY 700+ lumen SSC P7 3D Maglite modding, Lotsa pics!
« Reply #1 on: April 06, 2008, 07:01:38 PM »
Great job. :thumbup:

Offline 3rd_shift

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Re: DIY 700+ lumen SSC P7 3D Maglite modding, Lotsa pics!
« Reply #2 on: April 07, 2008, 01:45:00 AM »
I just charged some nimh D cell rechargeable batteries a little while a go and pulled them out of the fridge.
They measure 3.3 amps cold inside the light.

See that staircase?


This one.


See that new condo?


Look inside.


2 55 watt headlights versus a Seoul P7.


What's inside that pickup truck?


Nothing this time. ;)


See that building?


This building.


See that cat?


This kitty.


Well lit staircase.


More light added. ;)


Video of a walk outside with fancy flashlight.
http://smg.photobucket.com/albums/v313/3rd_shift/?action=view&current=SANY0142.flv

A walk into the forest.
http://smg.photobucket.com/albums/v313/3rd_shift/?action=view&current=SANY0148.flv

A walk back out of the forest.
http://smg.photobucket.com/albums/v313/3rd_shift/?action=view&current=SANY0149.flv

Back on apartment property.
http://smg.photobucket.com/albums/v313/3rd_shift/?action=view&current=SANY0152.flv
plantruler@hotmail.com
is my email and paypal address. :)
Observe and report what you saw with a good flashlight. ;)

Offline 3rd_shift

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Re: DIY 700+ lumen SSC P7 3D Maglite modding, Lotsa pics!
« Reply #3 on: April 08, 2008, 12:26:32 PM »
Just wanted to add this.

I had a cat for 21 years.
If you bring a bright light onto a cat slowly, it will close it's eyes like this black one did.
Notice that it's eyes in this case were shut and not shining back at the camera. ;)

Seriously;
It should however be noted that led lights are "instant on" and can indeed blind anyone before thier blink reflex can slam eyelids shut.
Please do not shine this light at anyone's eyes and especially don't turn on this light without warning on someone when they are looking in your direction.
There were such warnings on led lights far smaller than this a few years ago.
Those warnings are now more serious with todays brighter 700-900 lumen leds.
Even just the sidespill left a parts counter guy on my route in Tulsa, Ok seeing spots yesterday.
plantruler@hotmail.com
is my email and paypal address. :)
Observe and report what you saw with a good flashlight. ;)

Offline TOOCOOL

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Re: DIY 700+ lumen SSC P7 3D Maglite modding, Lotsa pics!
« Reply #4 on: April 09, 2008, 07:26:24 AM »
Very nice job and pics  :)  I think it might be wiser to drill the wire holes before installing the LED

Offline Essexman

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Re: DIY 700+ lumen SSC P7 3D Maglite modding, Lotsa pics!
« Reply #5 on: April 12, 2008, 03:32:51 PM »
Great tutorial Mr Shift !
I've been thinking about making one of these, I have a spare 3D mag and an old o sink. You have just shown me how to isolate the P7 with a Cree base, great idea that :thumbup:
OK, I've put it on my "to do" list.
Just need to buy some rechargable D cells now.
Thanks again.

Offline 3rd_shift

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Re: DIY 700+ lumen SSC P7 3D Maglite modding, Lotsa pics!
« Reply #6 on: April 12, 2008, 08:28:04 PM »
Very nice job and pics  :)  I think it might be wiser to drill the wire holes before installing the LED

You are right on with this observation. ;)
I had just centered the led when I noticed that the original holes were too close together. :(
Still, it was a perfect bullseye and decided to go ahead and let the adhesive harden and then deal with the drilling later in this case.

Drill before installing the led, it's easier. :)
plantruler@hotmail.com
is my email and paypal address. :)
Observe and report what you saw with a good flashlight. ;)

Offline 3rd_shift

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Re: DIY 700+ lumen SSC P7 3D Maglite modding, Lotsa pics!
« Reply #7 on: April 12, 2008, 08:31:22 PM »
Great tutorial Mr Shift !
I've been thinking about making one of these, I have a spare 3D mag and an old o sink. You have just shown me how to isolate the P7 with a Cree base, great idea that :thumbup:
OK, I've put it on my "to do" list.
Just need to buy some rechargable D cells now.
Thanks again.

Surprisingly, that little ceramic base does indeed transfer heat rather quickly from the moment I switch the light on.  :thumbup:
This appears to be proof that the rumored upcoming 4 die version of the Cree XRE on that same base should work ok. :)
plantruler@hotmail.com
is my email and paypal address. :)
Observe and report what you saw with a good flashlight. ;)

Offline Aircraft800

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Re: DIY 700+ lumen SSC P7 3D Maglite modding, Lotsa pics!
« Reply #8 on: April 13, 2008, 05:41:45 AM »
Another Great Tutoral 3rd_shift!

I have been working on a couple of new projects to show off, but I can't get my act together to start the next DFW Flashapoloza, job issues...

We sure miss you at CPF!

Offline nanotech17

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Re: DIY 700+ lumen SSC P7 3D Maglite modding, Lotsa pics!
« Reply #9 on: April 18, 2008, 03:49:09 PM »
 8)

Offline 3rd_shift

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Re: DIY 700+ lumen SSC P7 3D Maglite modding, Lotsa pics!
« Reply #10 on: April 19, 2008, 01:36:13 PM »
Just thought I would mention that a 3c Maglite done much the same way should also work fine.
3 c cell alkaline batteries might gag, but will kinda work.
Alkalines usually just can't cough up much more than 1.5 amps.
3 nicad or nimh rechargeable's are better.

Other possibilities for a mod like this are;
1c cutdown Maglite with a C cell sized  lithium ion battery from www.dealextreme.com , or an AW c cell should work.

1D cutdown Maglite with a single D cell Lithium ion from www.kaidomain.com .

The name of the game is getting close to 3.3-3.5 volts pushing through the led to keep it near it's rated 2.8 amp current flow rating.
The flashlight switch assembly has a slight amount of resistance, while voltage sag does the rest on smaller, alkaline, or lower to mid-quality batteries.

High quality 3.6-3.7 volt battery setups do need some slight resistance added to keep the led from overloading from excess current.
Some nicads, nimhs and lithium ions can really cough up a lot of current through this led without some slight added resistance.

All my old and beat up nicad and nimh D cells are doing just about perfect with no added resistance needed in my case.
Your batteries might be better quality than mine though.
« Last Edit: April 19, 2008, 01:42:03 PM by 3rd_shift »
plantruler@hotmail.com
is my email and paypal address. :)
Observe and report what you saw with a good flashlight. ;)

Offline warx

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Re: DIY 700+ lumen SSC P7 3D Maglite modding, Lotsa pics!
« Reply #11 on: April 19, 2008, 02:35:33 PM »
Thanks for the great thread.  :thumbup:  I have a couple more questions.

1. what kind of run time should be expected from 1x AW C size or 1x 18650?
2. What would the expected lumen's be from those combinations
3. What would be the cheapest route for cutting down a C size mag and rethreading.

edit for one more question  :D
Would it be possible to use the C mag host to reach the 900 or so lumens?
« Last Edit: April 19, 2008, 03:26:04 PM by warx »

Offline 3rd_shift

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Re: DIY 700+ lumen SSC P7 3D Maglite modding, Lotsa pics!
« Reply #12 on: April 19, 2008, 08:03:29 PM »
#1 Just under 1 hour with a good 18650 and about 1 hour with an AW C cell Lithium ion.
#2 About 700-900 lumens would be about right.
#3 This is a good question to ask at www.candlepowerforums.com in thier homemade and modified lights section.
Someone will step up and suggest a good place to send over a c cell Maglite for cutting down.
I wish I knew the current price.
Still, a 1c cutdown Maglite as bright as a 60 watt housebulb is definitely something worth showing to your friends. 8)

Quote
Would it be possible to use the C mag host to reach the 900 or so lumens?
You bet!
Heat will be the main issue at 10 watts though.
It's still quite a sight and worth showing off.
Plus, the c cell is water resistant and can quickly be cooled off with a garden hose for longer and cooler runtime.
In fact, I often leave my 3D standing in a large cup of water whenever I leave it on. ;)
Both the C and D cell Maglites are usually water resistant down to at least 5 feet in a swimming pool btw.
plantruler@hotmail.com
is my email and paypal address. :)
Observe and report what you saw with a good flashlight. ;)

Offline nanotech17

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Re: DIY 700+ lumen SSC P7 3D Maglite modding, Lotsa pics!
« Reply #13 on: April 20, 2008, 10:55:55 AM »
I finally made my own quad cree Q5 direct drive with download heatsink & running it with 1 x AW C li-ion with a spacer in a mag 2D and i'm getting 2.8A.That is 700mA each to the emitter - bright  :blinking:

Offline warx

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Re: DIY 700+ lumen SSC P7 3D Maglite modding, Lotsa pics!
« Reply #14 on: April 21, 2008, 12:58:06 AM »
I finally made my own quad cree Q5 direct drive with download heatsink & running it with 1 x AW C li-ion with a spacer in a mag 2D and i'm getting 2.8A.That is 700mA each to the emitter - bright  :blinking:

Wonder if a person could wire 2 cells in parallel for this kind of setup. Seems like you would have enough room and have twice the run time... right? Ive been thinking about that with a 2c. Using 2x aw C's or 2x 18650 in parallel on a p7.. 2hours of run time.... right? thinking out loud here  ;)