Microcool build sequence

[phburns]

I've been lurking around here for some time, gaining knowledge and drooling on the products that DIY's have produced.

Without any access to metal cutting machinery, I found a small heatsink and designed a light around it. With all the bits and pieces gathered together to build a few lights, I decided to document one of the builds. What follows is a pictorial display of a build pairing Quazzles quality L333's and Microcool's Southbridge chipsink as the foundation.

Parts used: microcool southbridge chipsink 30x30x30(mm)
LED/driver: L333-MC-XPEH50-B/L333-MC-XPGH51-B
Lens: 3-Up Cree XP-G Carclo 10507
Tactile Switch: digikey 401-1835-ND
Battery contacts: digikey 209K-ND
PCB .5mm socket: digikey 952-1461-ND (also used the matching pin for ease of soldering the wire on the pin)
Yellow Cable: Canare L-4E5C Mini-Star-Quad Microphone Cable
Fasteners: 3mm stainless steel screws (custom lengths from 16mm)
O-rings for base mount and waterproofing: http://www.oringsusa.com/
Batteries: 18650 protected panasonic Callies Kustoms (not shown)

Front cover, Base, and battery holder cast in Black Onyx from Smooth-On.com of my own design. Battery pieces superglued together.

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[Vancbiker]

Nice build!

That smooth-on.com place looks like an great resource for the DIY builder as well. A+

[mattthemuppet]

really neat build! The black bits are resin? I like the intricate moldings for the wires, o-rings etc.

[Toaster79]

That's just fantastic! Too bad the front cover ins't made of ali to help with some sinking. Love the creativity!

[Vancbiker]

The bezel and battery holders look like an SLA or other type of rapid prototyping process. Is that what you used to make a pattern for a molds?

[borrower]

Very cool. I had to look a few times to find your momentary switch.

[phburns]

Originally Posted by Toaster79

That's just fantastic! Too bad the front cover ins't made of ali to help with some sinking. Love the creativity!

It gets pretty warm on the kitchen table, I have no means of testing the temperature, but it never hit the boards heat limit. There's about 17 sq in. of heatsink area, with unrestricted draft.

[phburns]

Originally Posted by Vancbiker

The bezel and battery holders look like an SLA or other type of rapid prototyping process. Is that what you used to make a pattern for a molds?

Yes, I've got access to a rapid machine, although the parts are solid it does look like it's fresh off the printing platter in places.

Originally Posted by borrower

Very cool. I had to look a few times to find your momentary switch.

Yeah the switch is pretty small, a real bugger to solder up and get in the package, although it works quite well.

[emu26]

Fantastic build Mr Burns!

Just love seeing new designs, materials being shared here. It never ceases to amaze me just how many ways there are to skin a cat

[JezV]

Very neat. Must be very lightweight - there's not much metal in that heatsink. I guess the L333 must be ideal as you don't need to mount a separate driver anywhere. I might make one too!

[phburns]

Exploded View

[ThinkBike]

Really nice. The custom molded pieces are impressive.

Are the LEDs XPE or XPG?

It looks like you're running the 1 amp L333 series. What kind of run time do you get from the Callies Kustoms panasonic 18650 batteries?

[phburns]

I've got 3 of Quazzles boards with xpe's (hew) and 1 with xpg's, I haven't done a rundown test, but the calcs say around 2 hrs. I'll try to get the test done soon, and some beam shots up.

[ThinkBike]

Brilliant build. Thanks for the detailed photos. Nice combination of technology and simplicity.

Would love to see beam shots. If you have a way to measure temperature, would also like to see temp readings as well.

Bravo!