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  1. #1
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    Rubix - The Quad D-Bin P7 Light 3,600 lumens

    So with daylight savings coming to an end, if I figured it was time to bust out the bigger guns. Everyone seemed to enjoy my sharing of the Wall-E Dual Ostar light (http://forums.mtbr.com/lights-diy-do-yourself/wall-e-dual-ostar-light-2-000-lumens-505166-post6262966.html), so I thought I'd share Wall-E's new barlight companion, Rubix.

    For the design, I'm using (4) P7 D-Bin (900 lumens each theoretical) emitters, a hipFlex driver from Taskled, and Ledil Boom lenses. The lens choice comes from alot of experimenting to see which patterns I liked best. And since I already have a 2,000 lumen helmet spot light, I wanted Rubix to be really floody. I ended up on deciding to go with (2) smooth spot lenses aimed 10 degrees higher up than the (2) medium lenses mounted below the 2 smooth spots, which gives a great flood from close to the tire all the way out 30-40 feet or so.

    The design stage:
    Rubix - The Quad D-Bin P7 Light 3,600 lumens-rubix1.jpg

    Rubix - The Quad D-Bin P7 Light 3,600 lumens-rubix2.jpg

    Rubix - The Quad D-Bin P7 Light 3,600 lumens-rubix3.jpg

    Rubix - The Quad D-Bin P7 Light 3,600 lumens-rubix4.jpg

    Took a while to hack these parts out, but I'm pleased with the outcome:

    Front cover completed:
    Rubix - The Quad D-Bin P7 Light 3,600 lumens-rubix6.jpg

    Back cover completed:
    Rubix - The Quad D-Bin P7 Light 3,600 lumens-rubix5.jpg

    All parts completed:
    Rubix - The Quad D-Bin P7 Light 3,600 lumens-rubix7.jpg

    Time for a little color (anodize). Here are some of the parts in the acid bath, getting the ano treatment:

    Rubix - The Quad D-Bin P7 Light 3,600 lumens-rubix8.jpg

    Parts all anodized:
    Rubix - The Quad D-Bin P7 Light 3,600 lumens-rubix9.jpg

    Assembly stages: It was an absolute beyotch trying to get all the wiring crammed up inside the housing. You can see the voltage regulator and thermostat used to control the active cooling circuit mounted to the mid section of the housing with the P7's are mounted to:

    Rubix - The Quad D-Bin P7 Light 3,600 lumens-rubix10.jpg

  2. #2
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    Back housing assembly completed and LED's mounted using AAA:
    Rubix - The Quad D-Bin P7 Light 3,600 lumens-rubix11.jpg

    Ledil lenses installed. Two boom Smooth spots on top, two boom mediums on the bottom:
    Rubix - The Quad D-Bin P7 Light 3,600 lumens-rubix12.jpg

    I used O-rings and glass lenses from DX to seal from the elements:
    Rubix - The Quad D-Bin P7 Light 3,600 lumens-rubix13.jpg

    Completed pics!!!!!
    Rubix - The Quad D-Bin P7 Light 3,600 lumens-rubix14.jpg

    Rubix - The Quad D-Bin P7 Light 3,600 lumens-rubix15.jpg

    Rubix - The Quad D-Bin P7 Light 3,600 lumens-rubix16.jpg

    Yeah that's the fan in the back. Active cooling again.... my trademark
    Rubix - The Quad D-Bin P7 Light 3,600 lumens-rubix17.jpg

    And here's how it looks mounted onto the stem faceplate. I have a knob which unscrews and the entire light comes off real quick. I designed the bracket so that I could set my angle and not have to re-align it every time I put the light on the bike. Dowel pins line up the light mount to the stem faceplate, so it doesn't rotate:

    Rubix - The Quad D-Bin P7 Light 3,600 lumens-rubix18.jpg

    Rubix - The Quad D-Bin P7 Light 3,600 lumens-rubix19.jpg

    And shot of the duo tag team (Wall-E on the left, Rubix on the right). 5,600 lumens total:

    Rubix - The Quad D-Bin P7 Light 3,600 lumens-rubix27.jpg

  3. #3
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    Sooooooo, this thread is useless without beamshots right? Right?!

    Here they are.... all pics taken at "standard MTBR settings" of ISO-100, F4, 6 Seconds.

    I set the hipflex to multimode, so you could get the picture for all 5 levels. The max power is set to the hipFlex maximum of 2.8 amps.

    Control shot:
    Rubix - The Quad D-Bin P7 Light 3,600 lumens-rubix20.jpg

    Hipflex level 1:
    Rubix - The Quad D-Bin P7 Light 3,600 lumens-rubix21.jpg

    Hipflex level 2:
    Rubix - The Quad D-Bin P7 Light 3,600 lumens-rubix22.jpg

    Hipflex level 3:
    Rubix - The Quad D-Bin P7 Light 3,600 lumens-rubix23.jpg

    Hipflex level 4:
    Rubix - The Quad D-Bin P7 Light 3,600 lumens-rubix24.jpg

    Hipflex level 5:
    Rubix - The Quad D-Bin P7 Light 3,600 lumens-rubix25.jpg

    And just for $hits and giggles, here's Wall-E and Rubix on together (5,600 lumens):
    Rubix - The Quad D-Bin P7 Light 3,600 lumens-rubix26.jpg

    Questions? Comments? Do I win (for now)?
    Last edited by cosmoworks; 10-30-2009 at 11:42 AM.

  4. #4
    mtbr member
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    Insane....

  5. #5
    I spelled Knievel wrong
    Reputation: StevelKnivel's Avatar
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    Wow, that is really nice. Very nice machine work and anodizing and the mounting system is awesome! You win for now!

  6. #6
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    wow!

    cos,

    You bringing that behemoth out for the wednesday ride? Love to take a closer look.

    Bob

  7. #7
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    GOOD FRIGGIN APPLESAUCE!!!!!!!! I went blind just thinking about the amount of light your pouring onto the trail- have your started fires as you pass by dry brush?

    Beautiful machine work and design. Golf clap for you bro!

  8. #8
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    Good enough for me.........
    You're king of the pile for now. "Uneasy lies the head that wears a crown"

  9. #9
    aka RossC
    Reputation: ocean breathes salty's Avatar
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    I think that might be the most technically amazing light I have ever seen built here. The attention to detail is second to none and the finish product looks like it should be on display, it is almost too good to get covered in mud while biking. Congratulations on some stellar craftmanship

  10. #10
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    I just wet myseft. That's light porn if I ever saw it

  11. #11
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    WOW, I would like to think that the commercial stuff out there is as good and had as much design thought, since your using non bleeding edge Led's but that is truly art and the build quality is tops.

  12. #12
    Austin, TX
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    The attention to detail, especially inside, is incredible! Form and function are top. Maybe MTBR should make a new sub-forum called "Artisan Lighting"

  13. #13
    It's soil, not dirt!
    Reputation: jhitch's Avatar
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    Truly inspiring...hats off to you cosmo.

  14. #14
    lumen junkie
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    Can't wait to see the quad XPG 7up!

  15. #15
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    Quote Originally Posted by Rich_SC
    Can't wait to see the quad XPG 7up!
    Thats' how the game is played here now isn't it.!!

  16. #16
    what a joke
    Reputation: ozlongboarder's Avatar
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    Speechless!!! Seriously, that is an amazing light!
    blah blah blah

  17. #17
    mtbr member
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    Quote Originally Posted by ocean breathes salty
    I think that might be the most technically amazing light I have ever seen built here.
    The attention to detail is second to none and the finish product looks like it should be on display,
    it is almost too good to get covered in mud while biking. Congratulations on some stellar craftsmanship
    ..... +1, absolutely stunning! and the anodizing is beautiful
    ...Scun.thorpe, UK

  18. #18
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    Wow.

  19. #19
    www.hahntronix.com
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    Excellent looking light. The anodizing looks really slick.

    I have a few questions, if you don't mind:

    I'm assuming you drive the P7s in series? Any interest in a custom designed buck driver that could drive your P7s in a 2s2P configuration at 2.8 amps each P7 (or a bit more)? Allows for lower battery voltage. Or are you using a boost driver? What is the interior dimension of your driver space. My driver is roughly circular and fits in a 1.25 inch diameter space.

    How do you like the BOOM reflectors compared to the Fraens you used on the Wall-E. I've built a few P7 lights using the Fraen OSTAR reflectors you used and was pleased with the results. How do the BOOMs compare? I've tried the MCE version and been a bit disappointed, they just produce a wall of light. Your beam shots look awesome, but the center looks kind of washed out. Do you get a center spot?

    Mark
    Last edited by mhahn@hvc.rr.com; 10-30-2009 at 04:17 PM.

  20. #20
    Go faster!
    Reputation: sergio_pt's Avatar
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    OK YOU WIN, I SURRENDER!

    It is perfectly built! Congrats you have great skills.

    What battery pack are you using to power all that?

    hmm why didn't you use a quad OSTAR? more lumens!!

    Do you have any plans for the XP-G?

  21. #21
    One Gear
    Reputation: .40AET's Avatar
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    WOW! The machining is absoulutely beautiful. Love the mount. The lumen race has escalated to a new level.

    Nice job!

  22. #22
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    Hey thanks for the kind comments everyone!!!!!


    Quote Originally Posted by il2mb
    You bringing that behemoth out for the wednesday ride? Love to take a closer look.
    Yep, see you on Wed Bob!

    Quote Originally Posted by mojojojoaf
    I went blind just thinking about the amount of light your pouring onto the trail- have your started fires as you pass by dry brush?
    No fires... yet!

    Quote Originally Posted by ocean breathes salty
    I think that might be the most technically amazing light I have ever seen built here. The attention to detail is second to none and the finish product looks like it should be on display, it is almost too good to get covered in mud while biking. Congratulations on some stellar craftmanship
    Thanks ocean. Trust me, I'm gonna cry if I ever crash on the bike and scratch Rubix up. The finish came out way better than I hoped for... I'm getting this finishing/ano stuff really dialed in now.

    Quote Originally Posted by odtexas
    Quote Originally Posted by Rich_SC
    Can't wait to see the quad XPG 7up!
    Thats' how the game is played here now isn't it.!!
    Don't laugh... that just might happen! For now I'll enjoy the glory of the crown.... at least for another couple weeks?

    Quote Originally Posted by mhahn@hvc.rr.com
    I'm assuming you drive the P7s in series? Any interest in a custom designed buck driver that could drive your P7s in a 2s2P configuration at 2.8 amps each P7 (or a bit more)? Allows for lower battery voltage. Or are you using a boost driver? What is the interior dimension of your driver space. My driver is roughly circular and fits in a 1.25 inch diameter space.

    How do you like the BOOM reflectors compared to the Fraens you used on the Wall-E. I've built a few P7 lights using the Fraen OSTAR reflectors you used and was pleased with the results. How do the BOOMs compare? I've tried the MCE version and been a bit disappointed, they just produce a wall of light. Your beam shots look awesome, but the center looks kind of washed out. Do you get a center spot?
    Yep, all in series. Thanks for the offer, but my battery packs are all 18.5V packs, so running 4-up doesn't present a voltage problem for me. My light is designed to use TaskLED's hipflex driver, which is 1.4" diameter. The driver cavity is the light is alot larger than the driver itself mainly to accomodate all the wiring for active cooling circuit.

    I like the BOOM lenses alot. They're VERY floody which is why I chose them. Even the spot BOOM lens doesn't focus nearly as well as the Fraen lenses do on on Wall-E, but that's what I wanted was a very floody beam. It doesn't have great throw, but I didn't want that, since I have Wall-E for throw, and I just wanted this light to light up everything immediately in front of me.

    The beamshots look washed out, because the "standard MTBR camera settings" probably don't work for lights in the several-thousand-lumens range. I propose the MTBR community standardize on a newer "high power standard camera settings" for lights 3,000 lumens and up (maybe all the same settings but just use 2-stops smaller aperature at F8?) In reality, your eyes adjust and it doesn't look like a bright washed out spot, it actually looks like a nice even wall of light.

    Quote Originally Posted by sergio_pt
    OK YOU WIN, I SURRENDER!

    It is perfectly built! Congrats you have great skills.

    What battery pack are you using to power all that?

    hmm why didn't you use a quad OSTAR? more lumens!!

    Do you have any plans for the XP-G?
    Haha! Thanks man! I'm using the same pack that I use to power Wall-E, 18.5V pack made up of ten li-ion 18650 cells. Trust me, I thought about doing quad ostars, but I wanted to keep this light on the smaller side, and the P7/Boom lens combo fit the bill.

    All this XPG 7-up stuff on the forums recently is grabbing my attention though. Rich_SC's idea of quad 7-up's doesn't seem so bad. I have a way-outside-the-box idea of how to cool it too, but need to research further. Damn this forum!!!!! I've got many ideas floating around in my head, and so little time to build!!!

  23. #23
    Single Speed Junkie
    Reputation: crux's Avatar
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    Very nice work. Keep thinking of dusting off the mill and giving it another go. With your latest build I might just give it a shot. Don't think I'll shoot for the crown though...

  24. #24
    what a joke
    Reputation: ozlongboarder's Avatar
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    I just came back for another look! I'm still blown away!

    If you do some more beam shots could you put some markers out to show different distances?
    blah blah blah

  25. #25
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    That's a beautiful light cosmoworks.

    I suppose you have some kind of grader blade built onto the rear of your bike too..... to sweep up all the melted rocks on the way through.

    That's nice.

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