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  1. #1
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    Honey I Shrunk the Tripple XM-L

    Instead of design something new, I shrunk my tripple XML housing to accomodate a Ledil LXM RS, optic U2 bin XM-L and a Lflex..
    I boiled it for 31 days and manged to get it small enough for a helmet light
    A few pics
    Main Body

    Front Bezel

    Comparison with the tripple


    77grams excluding a remote switch

    Ledil LXM RS optic

    Rear end, Lumberg M8 and M6 gland for remote switch


    Happy New Year...
    Last edited by Goldigger; 12-31-2011 at 06:51 PM.

  2. #2
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    I knew you were up to something as you were a little too quiet. Lovely job Jay, looks fantastic. Off to the ano tank now I guess for a splash of colour. The things you can do with a rotary table and a mill

    I am impressed you are getting anything done with the new edition. Must have excellent time management

    I got 3 lflex board the other day to play with so looks like we are all thinking along similar lines .

  3. #3
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    Cheers Brad,
    I wish i had the energy tonight to put it through the ano tank.. Broken sleep from the little man keeping us awake at night is zapping me!
    When i do have any spare time i cant be bothered to do anything, as im knackered...I've had to mill another tripple housing, so while i had the rotary table set up i milled the tripple and this mini version..


    Can't make my mind up what color i ahould ano this light, my helmet is blue so maybe it should be blue..

    Still need to knock up a mount and remote switch, they will both be out of delrin...

  4. #4
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    Smile

    Nice machine work!

  5. #5
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    Nice work! Perfectly matching in appearance, going to be interesting to hear how you like its output paired with the tripple.
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  6. #6
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    Will 2 18650 in parrallel be able to provide enough current to the lflex, to run a single xm-l @3amps?

  7. #7
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    Quote Originally Posted by Goldigger View Post
    Will 2 18650 in parrallel be able to provide enough current to the lflex, to run a single xm-l @3amps?
    Yes, they should have no problem. How long is your power cable? Small gauge cable at 3A can cause a fair bit of voltage drop. Beautiful light BTW.

  8. #8
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    Aww, GD's made another cute li'l baby

  9. #9
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    I love that Industrial look.
    Those cable connecters look great too.
    Good job.

  10. #10
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    Quote Originally Posted by Vancbiker View Post
    Yes, they should have no problem. How long is your power cable? Small gauge cable at 3A can cause a fair bit of voltage drop. Beautiful light BTW.
    I checked the tech docs for the lumberg m8 connectors I use, but there's no mention of the guage wire used...just rated at 4 amps..ill have a stab at 22/24 gauge wire.

    How long would you say is a good length to run the cable at?
    I planned to put the battery pack in the top of my camel back.

    Thanks..

    I'll hopefully get it Anodised this weekend, for some reason my m5 taps say bottom on the little boxes, but there all taper!
    So had to order another set so i can tap the hole properly for the mount..

  11. #11
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    Quote Originally Posted by Goldigger View Post
    I checked the tech docs for the lumberg m8 connectors I use, but there's no mention of the guage wire used...just rated at 4 amps..ill have a stab at 22/24 gauge wire.

    How long would you say is a good length to run the cable at?
    I planned to put the battery pack in the top of my camel back.

    Thanks..

    I'll hopefully get it Anodised this weekend, for some reason my m5 taps say bottom on the little boxes, but there all taper!
    So had to order another set so i can tap the hole properly for the mount..
    With such a tiny light, why don't you mount the batteries on the back of your helmet. You can keep the cable runs short this way. I found that it's well balanced so the weight's not a big issue.

  12. #12
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    Quote Originally Posted by Goldigger View Post
    Will 2 18650 in parrallel be able to provide enough current to the lflex, to run a single xm-l @3amps?
    as long as you use decent Japanese cells (Panasonic, Sanyo etc), it should be fine. Avoid cheap Chinese *fire cells though, they can't provide the current.

    I agree with Ofroad'bent - attach the battery to the back of your helmet. It'll weigh ~150g after waterproofing, which should balance out the light+mount at the front. I put mine on the webbing at the back, although I'd love to make some kind of battery quick release as I'm always swapping between my commuter light and my mtb light, both of which have the battery on the back. I've ridden with a helmet light for 10+ years and not having the battery in the camelbak is priceless, well worth the slight extra weight up top.

    oh, beautiful looking light too

  13. #13
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    Voltage drop calculator here.

    OEM Power Supplies - Voltage Drop Calculator

    I set my helmet cable length based on my battery being in my jersey pocket. It ends up being around 3.5 feet.

  14. #14
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    OfRoad & Matt do you have any pics of your helmet light setups?
    I thought of putting the batteries on the rear...i might make a minimal housing for two 18650's out of some delrin, hopefully it wont weigh to much but will be water tight..

  15. #15
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    Quote Originally Posted by Vancbiker View Post
    Voltage drop calculator here.

    OEM Power Supplies - Voltage Drop Calculator

    I set my helmet cable length based on my battery being in my jersey pocket. It ends up being around 3.5 feet.
    Great calculator.

    The biggest issue with the M8 connectors is that most of the only have a conductor size of 0.25mm≤ (24awg) so the max current capacity is only 3-4 amps so voltage drop is going to be around the 0.2-0.3volts if the cable is around 3 feet. Mount the battery on the helmet and drop is only getting 0.03v drop.
    Last edited by brad72; 01-03-2012 at 04:32 PM. Reason: retarded typing

  16. #16
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    Quote Originally Posted by brad72 View Post
    Great calculator.

    The biggest issue with the M8 connectors is that most of the only have a conductor size of 0.25mm≤ (24awg) so the max current capacity is only 3-4 amps so voltage drop is going to be around the 0.2-0.3volts if the cable is around 3 feet. Mount the battery on the helmet and drop is only getting 0.3v drop.
    Correct me if im wrong but 0.2-0.3volts doesnt sound like anything to worry about?

  17. #17
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    Quote Originally Posted by Goldigger View Post
    OfRoad & Matt do you have any pics of your helmet light setups?
    I thought of putting the batteries on the rear...i might make a minimal housing for two 18650's out of some delrin, hopefully it wont weigh to much but will be water tight..
    Hi Jay. I use the industrial 3M dual lock to mount my lights and batteries. This way if I hit a big branch the light and battery will get ripped off and not my head. The velcro is plastic, not fabric so it takes a lot of force to break it free.

    In the picture below you can just see a 14,8v pack on the back of the helmet. It was held on with a cable tie through the heatshrink but now I use the dual lock. Weight wise I cannot tell is is there but since you are going to use only 2 cells if will not even be noticeable.


  18. #18
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    Quote Originally Posted by Goldigger View Post
    Correct me if im wrong but 0.2-0.3volts doesnt sound like anything to worry about?
    I don't see a real problem but with the lflex since you are driving 1 led to 1 cell, adding your voltage drop the lflex might only be getting 3.9v. At 3A current the xml draws 3.5 volts so it will not stay in regulation when the li-ion cell gets down to it's nominal voltage of 3.7 volts (lflex getting 3.3v) ........it think

    But put the pack on your helmet and voltage drop is only 0.03v so no problem at all (note typing error in post above from retarded typing angers)

  19. #19
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    Quote Originally Posted by Goldigger View Post
    Correct me if im wrong but 0.2-0.3volts doesnt sound like anything to worry about?
    It's not the end of the world for sure, but it is .75W of energy lost to the light. That is ~4% of your 2P battery's capacity.

  20. #20
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    Dont forget in the grand scheme of things that the Lflex is a linear driver and as such is burning off excess volts as heat anyways and most efficient when close to the leds voltage


    Nice mini me light there Jay

  21. #21
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    Quote Originally Posted by Goldigger View Post
    OfRoad & Matt do you have any pics of your helmet light setups?
    I thought of putting the batteries on the rear...i might make a minimal housing for two 18650's out of some delrin, hopefully it wont weigh to much but will be water tight..
    Here's my set-up. The batteries are wrapped in shrink-wrap, the ends sealed with plasti-dip, so they're 100% waterproof. I bonded some velcro to the battery packs, and they are secured to the helmet with a stretchy velcro strap that came with a Planet Bike flasher.

    The light mount is secured with 3M Dual-lock to the helmet, and also with a loop of Velcro One-wrap around it.



    I leave this on the helmet all the time this season, and use my spare helmet for the rare daytime ride.

  22. #22
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    I'll take a pic of both my commuter set up and my mtb set up tomorrow before my night ride, although it looks a lot like brad's, with the battery vertically mounted on the back vents. A 2 cell I barely notice and the 3 cell is liveable (and easily worth not having the hassle of being tied to my camelbak).

  23. #23
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    Scar has a nice simple set-up:


    My green helmet is fairly rounded, so the battery didn't sit well vertically.

  24. #24
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    Very nice looking light!


    Yep, mounting the battery on the back of thel helmet is the way to go!

    I can't believe it has been over 4 years now, but I would never go back. Actually, I think I was the very first one to do it. At the time, everyone was trying to out build each other with monster lights and I went the exact opposite direction, small and lightweight.

    Here is the link to the original thread - http://forums.mtbr.com/apparel-prote...ed-354430.html Funny, not too many of the current regulars around back then, noticed msxtr was around back then

    Industrial Strength Velcro is all I use




    You should have no problems running a 2P battery configuration. I have been running a 2S2P configuration for my 4x XM-L bar light (2S2P) for quite a while now and have not seen any problems


    Thanks Ofroad'bent, just saw your post as I was previewing mine


    ****

  25. #25
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    I have a ton of these velcro cable ties at home, they should be strong enough at holding everything on the helmet..


    Cheers for the pics of your setups, helps me to see where your placing everything

  26. #26
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    Quote Originally Posted by Goldigger View Post
    I have a ton of these velcro cable ties at home, they should be strong enough at holding everything on the helmet..


    Cheers for the pics of your setups, helps me to see where your placing everything
    That's basically what I'm using around the base of my light mount. The Dual Lock goes under the mount and on the helmet, then this stuff goes over the mount and around the helmet for extra security.

    Here's a pic of the other side if it helps.

  27. #27
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    I was tempted to try one of this 1S 3.7v lipo's but think they may be a bit on the long side at 128mm.
    But could be an easy battery to waterproof..plus there only $9
    HobbyKing R/C Hobby Store : Turnigy 5000mAh 1S 20C Lipoly (Single Cell)
    Spec.
    Minimum Capacity: 5000mAh
    Configuration: 1S / 3.7v / 1Cell
    Constant Discharge: 20C
    Cell Weight: 114g
    Cell Size: 128 x 42 x 10mm

  28. #28
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    Quote Originally Posted by Goldigger View Post
    I was tempted to try one of this 1S 3.7v lipo's but think they may be a bit on the long side at 128mm.
    But could be an easy battery to waterproof..plus there only $9
    HobbyKing R/C Hobby Store : Turnigy 5000mAh 1S 20C Lipoly (Single Cell)
    Spec.
    Minimum Capacity: 5000mAh
    Configuration: 1S / 3.7v / 1Cell
    Constant Discharge: 20C
    Cell Weight: 114g
    Cell Size: 128 x 42 x 10mm
    Personally I'd want to see that in some kind of hard case to protect it from getting bent or punctured. Lipo packs get especially dangerous when damaged and the last thing you want within inches of your head is an angry Lipo pack!

    How about either of these?

    HobbyKing R/C Hobby Store : ZIPPY Flightmax 6200mah 1S 30C Hardcase Car Lipoly

    HobbyKing R/C Hobby Store : Turnigy nano-tech 5000mah 1S2P 50~100C Hardcase Lipo Pack

  29. #29
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    Quote Originally Posted by kwarwick View Post
    Personally I'd want to see that in some kind of hard case to protect it from getting bent or punctured. Lipo packs get especially dangerous when damaged and the last thing you want within inches of your head is an angry Lipo pack!

    How about either of these?

    HobbyKing R/C Hobby Store : ZIPPY Flightmax 6200mah 1S 30C Hardcase Car Lipoly

    HobbyKing R/C Hobby Store : Turnigy nano-tech 5000mah 1S2P 50~100C Hardcase Lipo Pack
    +1 for what kwarwick said. A punctured lipo on the back of the helmet would not be the best, although I imagine it could be quite spectacular if a fireball ensued. I am sure it would go viral on youtube if you were lucky enough to record it.

    I used the zippy lipo batteries a lot and found them to be very good.

    This poor bugger was charging lipo's on his car and think something went wrong, can't put my finger on it though. Perhaps that is why I charge my lipo's outside The guy in the background looks like he is warming his hands by a campfire. Can you imagine the phone conversation to his wife when he asks for her to come ad pick him up.


  30. #30
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    Added a splash of color ...
    Looks pretty close to my blue hope pro 2 hubs




  31. #31
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    And I thought the Easy2DIY was a pretty sharp looking light. This one is awesome!

  32. #32
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    Quote Originally Posted by Ofroad'bent View Post
    And I thought the Easy2DIY was a pretty sharp looking light. This one is awesome!
    Agreed!

    You may have quite a few folks wanting one to go with the excellent Tripple's you've built for us. I know I'm tempted -- eagerly awaiting beamshots.
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  33. #33
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    Quote Originally Posted by Ofroad'bent View Post
    And I thought the Easy2DIY was a pretty sharp looking light. This one is awesome!
    Thanks
    Must admit when i dipped it in the dye the first few dips, my heart sank as it looked like the dye wasn't taking...then the magic happened with every dunk after and I called the Mrs in to look at the color..even she was impressed.



    Quote Originally Posted by ecthelion View Post
    Agreed!

    You may have quite a few folks wanting one to go with the excellent Tripple's you've built for us. I know I'm tempted -- eagerly awaiting beamshots.
    Hi Kipp, thanks
    I'll try to get some beam shots up over the weekend, all its done lately is pee down with rain here.
    I'll combine the shots with the tripple at level 3 and 5, with this light set to the full 3 amps..
    That way we should see if it serves its purpose as a helmet light..

  34. #34
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    looks fantastic Jay. I know that feeling of "crap the dye isn't taking". It's bizarre how just another 30 seconds in the dye makes all the difference and the colour suddenly starts to develop.

  35. #35
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    That looks great!

  36. #36
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    Smile

    You may have quite a few folks wanting one to go with the excellent Tripple's you've built for us. I know I'm tempted -- eagerly awaiting beamshots.
    This.

    I wish to know how you can find the time to keep producing these lovely lights Goldigger with your new arrival. You either have a very understanding partner or you can operate on 2hrs sleep a night!!

  37. #37
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    Quote Originally Posted by ruscle View Post
    This.

    I wish to know how you can find the time to keep producing these lovely lights Goldigger with your new arrival. You either have a very understanding partner or you can operate on 2hrs sleep a night!!
    Hi Russell,
    I've had this and another tripple on the go over the last two and a half weeks, I've just squeezed time in where i can..I've still got to get the tripple anodised and wired up for next Tuesday.
    And yes I'm knackered with all the broken sleep..

  38. #38
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    Ah yes, the joys of broken sleep. Just wait till he sleeps through the night for the first time. You'll still wake every couple of hours to check on him.

    At least it explains why you're posting replies in the middle of the night.

  39. #39
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    wow, that's pretty and I love blue!

    A bit late to the party, but here are my helmet light set ups:

    mtb


    commuter

  40. #40
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    Wow GD, that's a beautiful little light. Love the colour, too. Very impressed

  41. #41
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    I decided to wire it up tonight, still need to make a mount and modify one of my remote switches so it can be attached to the helmet.

    As usual the holder on the optic needs a tweek, i drilled two holes in the holder to allow the wires in and then into the little cavity over the solder tabs.



    Dam those lflex's are a bugger to solder as there so small!

    Turned it on and thought that the blue anodising was reflecting into the beam, as there was a strange beam pattern only on high.
    So i removed the front bezel, still the same!
    Then i thought the blue wire must have been touching the optic as the beam looked blue, but still only on high.
    So i carefully popped the optic out of its holder...and this is what i found..


    Had to take it all apart and stick another led in..now the beam looks fine..beam shots hopefully tomorrow night.
    Temporary battery pack..hopefully that should provide enough juice to the lflex for the beamshots?

  42. #42
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    Wow Jay she certainly blew out. I though at first you had de-domed it until I read the thread. Any idea's what went wrong?

    Your light certainly looks sweet though. The blue has come out perfectly

  43. #43
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    Probably a dumb question, but...

    What voltage are you running this thing at? I can't tell if those batteries are all in parallel or not.

    The l-flex is optimised for 3.5v or so. I know more shouldn't hurt it, but it needs to burn off all the excess as heat. Could that have cooked something if you're running too high a voltage?

  44. #44
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    Battery pack is 1S4P 3.7v
    I'm just charging the cells individually at the moment so i'll see what the true capacity is of each cell.
    But i'm using this config as yeti and matt have said that these cells struggle to deliver over 1.7amps..

    I just think it may have been an iffy led.. other than that i have no clue why it happened.

  45. #45
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    First trustfire just finished charging at 1amp..capacity 1511mah
    Now its on a 1amp discharge, it went from 4.2v - 3.82 in about 5 seconds.. doesn't look very promising to me.

  46. #46
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    Beautiful light. Red did not entice me to anodize, but this blue....

    Sorry about the XM-L & Trustfire. Sux lux.

    BrianMc

  47. #47
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    Thanks Brian..

    I charged one of the trustfires up, with my turnigy accucell charger, followed by a discharge and charge.
    These are trhe figures:
    1 amp charge 4.20v capacity 1511
    1 amp discharge 3.00v capacity 1568
    1 amp charge 4.20v capacity 1440

    edit: second cell just finished a 120min charge 4.20v capacity 1490

    Looks pretty crap to me..not sure if i did it correct.
    Finsihed the switch, can tie it to my helmet with a velcro cable tie


    Beamshots..

    Tripple XML at 3amps (cute SS optic)

    Tripple XML at 3amps (cute SS optic) plus Honey i shrunk the tripple XML.
    I noticed that the shadows are gone in front of me..

    Same again but looking slightly right

    Same again looking slightly left

    And on its own with out the monster tripple XML


    Here's a Gif to show the difference between the Tripple XML on it's own then with this light..
    Last edited by Goldigger; 01-07-2012 at 02:33 PM.

  48. #48
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    Great little switch Jay and the helmet light definitely compliments the triple xml.

    Beautiful light. Red did not entice me to anodize, but this blue..
    Brian you either like red or you don't. On a fully black bike it looks fantastic but the problem is with having yellow, orange, violet, blue and green ano dye's what colour to do next

  49. #49
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    interesting idea about the optic holder, must have made things a lot quicker. Odd that the LED blew up, fingers crossed it was just a flaw with the LED.

    Bummer about the batteries, that was worse than I expected (although going from 4.2 to 3.8V very quickly is normal, as is going from 3V to ~3.5V on a charge) The unprotected ones seem better as I've had ~8 of each Trustfire and Uniquefire 2500 come through my hands and they've all come to ~2250mAh, with little variation. I guess the lower capacity is where you pay for the PCB at more or less the same price. They'd still make decent spare buck batteries or for torches/ headlamps if you can stick to 1/2C per cell discharge. I'd offer to buy a couple off you, but there's probably not much point with Royal Mail prices..

  50. #50
    A waste of time it is is
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    [QUOTE=brad72;8888901 On a fully black bike it looks fantastic but the problem is with having yellow, orange, violet, blue and green ano dye's what colour to do next[/QUOTE]

    tie-die rainbow?

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