Results 1 to 10 of 10
  1. #1
    mtbr member
    Reputation:
    Join Date
    Jan 2004
    Posts
    177

    RC motor heatsink for MR 11 housing

    In preparation for my Cutter MR 11 kit, I connected a Radio Control car motor heatsink to the housing. I used artic silver epoxy as the coupling material. To get the heat out of the housing to this heatsink, I also purchased the KHS35 heatsink. I plan to drill and tap the KHS35 heatsink, and install copper screws to tranfer the heat to the housing heatsink.

    Let me know you thoughts.

    DFH
    Attached Images Attached Images

  2. #2
    mtbr member
    Reputation: dnlwthrn's Avatar
    Join Date
    Jan 2006
    Posts
    1,241
    I think with that heatsink, you won't really need the other one. You just need a solid piece of aluminum or copper or something to transfer the heat from the back of the LEDs to the case.

  3. #3
    mtbr member
    Reputation: Nathan Cloud's Avatar
    Join Date
    Jul 2005
    Posts
    300
    I say NICE! We built these pups:

    http://www.racedaynutrition.com/features/bikelight.aspx

    Which employ the same approach! Good cheap way to dissapate heat IMO, plus i think it looks pretty slick

    Though mine did catch fire...
    Crankfire.com / New Englandish Mountain Biking Community

  4. #4
    Singletrack Daydreamer
    Reputation: rockymtnway's Avatar
    Join Date
    Nov 2004
    Posts
    346
    Nice looking unit. Great idea.
    Train 'til you puke. Cheat to win. Party like a rockstar. We miss you, Jan!

  5. #5
    mtbr member
    Reputation:
    Join Date
    Jan 2004
    Posts
    177

    Done...and it is brite!!!

    Finished the project tonight.

    Picture 1, copper pieces silver epoxyed to fatman heat sink. Later silver epoxyed to copper bar at rear of housing for heat transfer.

    Picture 2, copper heat transfer rod (wire) coming out of housing. Rods were silver epoxyed during final assemby to RC heat sink. (#8 bare copper wire from home depot)

    Picture 3, copper heat transfer rod shown fitting into back of heat sink. Added heat transfer ceramic paste at final assembly.

    Picture 4, finished product on floor.

    Picture 5, finished product on helmet.

    Few issues, KHS35 heat sink needed center hole drilled out larger, three outer holes needed drilling for optic piece to fit. I assume this is because of one of first R2 LED production runs??

    Fatman is SMALL!! Had to buy smaller solder iron to do this work.

    Ran for 15 min in house with no fan, 1000mA, 70 degrees farenheit. Copper transfer bars got very hot, could touch but not hold. Heatsink got very warm but could be held in hand. Set it up with two levels of output, 600mA and 1000mA.

    Great project, time to ride!!!! .
    Attached Images Attached Images

  6. #6
    mtbr member
    Reputation: gubawatts's Avatar
    Join Date
    Aug 2004
    Posts
    73
    Dirkfh,

    Nice design! How do you install the light assembly into the housing with the copper rods attached? Or do they go in after the light head is installed into the housing?

  7. #7
    mtbr member
    Reputation:
    Join Date
    Jan 2004
    Posts
    177

    The rods are silver epoxed.

    The rods are silver epoxed in then the LED board/optic/heatsink are installed.

    Since the pictures were taken, I replace the rods with 1/2" longer versions and re-epoxed them in. The ceramic heat transfer paste has been replaced with a silver based version. And lastly the screw-on cover that holds all the pieces in, has been opened up more. I found it was blocking some of the light out-put.

    I will try to post some beam shots soon.

    DFH

  8. #8
    mtbr member
    Reputation:
    Join Date
    Jan 2004
    Posts
    177

    Beam shots, one of three.

    Picture of the project as of now and beam shots at 20' increments and 600mA and 1000mA currents.

    1. 600mA@20'

    2. 1000mA@20'

    3. Finished product (Frankenlight as my buddies call it).

    This is no overvolted MR11 anymore !!!

    DFH
    Attached Images Attached Images

  9. #9
    mtbr member
    Reputation:
    Join Date
    Jan 2004
    Posts
    177

    Beam shots 2 of 3

    Two of three.

    1. 600mA@40'

    2. 1000mA@40'

    3. 600mA@60'

    4. 1000mA@60'
    Attached Images Attached Images

  10. #10
    mtbr member
    Reputation:
    Join Date
    Jan 2004
    Posts
    177

    Three of three

    1. 600mA@80'

    2. 1000mA@80'

    3. 600mA@100'

    4. 1000mA@100'

    Throughly impresssed with this mod. My night riding speed has increased substantially because of the ability to SEE.

    DFH
    Attached Images Attached Images

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •