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  1. #1
    A waste of time it is is
    Reputation: emu26's Avatar
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    Some bar stock, 3 MC-e's and a Maxflex 3

    So I spent months trying to work out how I could drive a triple MC-E with my existing 14.8v batteries. I found a couple of possible drivers but all had their problems. In stepped StevelKnivel that assured me I could use a maxflex to drive two parallel strings of 6 die. This would only give each string 600mA, not the 700mA I greedily wanted, but this was the best option by far. Thanks StevelKnivel

    This was to start as a simple build using lots of aluminium "flat bar" laminated together to make the light body to house a triple MC-E build. Then it was suggested that a laminated body was not a good heat sink, something about junction temps Thats where it stalled.

    Then Troutie offered lots of encouragement and advise. Below is the build details of what followed.

    Step 1
    Plan what you are building. I used this program http://www.cadlogic.com/products/draftit/
    Thanks again Troutie
    Sorry but I can't post my drawing. If you want a copy then PM me, but you will need to download the above program

    Its easier with pics

    MTBR Build Pg1.jpg

    MTBR build pg 2 .jpg

    MTBR pg 3 .jpg

    MTBR page 4 .jpg

    Beamshot Comparison MTBR.jpg

    Hope I haven't bored you all. Trail pics and video, the real reason I built this, will follow in the not too distant future.

    Thanks heaps to Steve, Smudge for the heads up on the wire, my mate Rob who insisted this couldn't be done (it only made me more determined) and of course Troutie. Much appreciated.
    Attached Images Attached Images

  2. #2
    mtbr member
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    WOW FANTASTIC WRITE UP AND BUILD THERE STU

    I cant wait to see the video
    Last edited by troutie-mtb; 12-02-2008 at 01:17 PM.

  3. #3
    Off the back...
    Reputation: pinkrobe's Avatar
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    Uh, wow! What kind of blade do you have on your saw?
    @pinkrobeyyc
    #pinkrobeyyc

  4. #4
    aka RossC
    Reputation: ocean breathes salty's Avatar
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    One of the best write ups I have read emu, Well done. The light looks pretty darn bright too... I bet you are happy with it

    How are you finding the beam and what optics went into it... apologies if that is listed in the post somewhere, I went looking but couldn't find it.

  5. #5
    At Work
    Reputation: sxr-racer's Avatar
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    http://www.mytoolstore.com/klein/59001.html

    You needed one of these. I would think after the time you spent drilling all those holes that the cost of one of these would have paid off!!!!!!!!!

    Looks good.

  6. #6
    mtbr member
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    Great looking light, that is a very clever case design!

  7. #7
    100% italian mtbiker
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    which lenses for your Old and New builds?

  8. #8
    I spelled Knievel wrong
    Reputation: StevelKnivel's Avatar
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    Very nice write up and awesome light! I'm glad the maxFlex is working for you!

  9. #9
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    An inspiring write-up, and an awesome light. Well done!

    Out of curiousity, how did you cut the screw-threads in Step 7? Is it worth the trouble to use taps & dies, or simply drill & cut threads using steel-bolt itself?
    Last edited by hootsmon; 12-02-2008 at 03:52 PM.
    Brisbane, AU

  10. #10
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    I would highly recommend using a tap for the treads, otherwise you might never get the bolt out of the galled aluminum.

  11. #11
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    Nice job. Great photos!

  12. #12
    A waste of time it is is
    Reputation: emu26's Avatar
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    Thanks guys for all the positive feedback

    Now to try and answer the questions

    Pinkrobe,
    I'm using the standard blade that came on my Metabo compound saw. It is a 210 x 2.8 x 30mm 42T blade. The teeth have a negative rake on them. The important thing to remeber when cutting the aluminium is to not try and take too much at once. The fins are 5mm deep but each groove was cut with about three passes. Its also important to remember to use lots of lube. The blade was regularly sprayed with WD40

    Ocean Breathes Salty,
    Wrapped with the output, but not so the beam patterns. I used the XR-E XLSL -7090- 247 optics from cutter. It currently has 2 x 8* and a 25* in it. The 8* have very noticeable donuts and have an overall useable beam width almost identical to the 25*. The overall beam is quite wide but I wanted more of a flood pattern because this will primarily be used for night videos with my GoPro cam. I'll reserve final judgement at the moment till its been on trail

    SXR-Racer,
    Nuh what I needed from the start was one of these
    Drill clamp.jpg
    it made a huge difference to how quickly I was able to drill everything out. Next time though I wouldn't do the perimeter drilling like that, it was a PIA

    mdsjack,
    new lenses, see my response to Ocean Breathes Salt. The old lenses are the square Ledil ones from Cutter. From memory a SS, Diffused and Medium

    Hootsmon,
    as kgardnez said, definitely use a tap and die set. I got this Frost set
    Tap n die set.jpg
    from Bunnings for about twice the price of what I paid for the individual "taps" I bought, which were the ones I broke.

    Again, thanks for all the positive feedback.

    Night video will follow, the real test

  13. #13
    mtbr member
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    Quote Originally Posted by emu26
    you wont see on the night trails till early next year when I return from the states,

    what so no video till then

  14. #14
    Beany
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    Hi Emu26 / Stuart,

    Great work when will you next be out for a night ride so I can join you.

  15. #15
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    Nice looking light. Your writeup looks better than most product manuals.

  16. #16
    A waste of time it is is
    Reputation: emu26's Avatar
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    Thanks Cytoe, my mates reckon I like the sound of my own voice so maybe that helps

    Oh look, there's one of them now.
    Hi Beany, sadly you won't see me on the night trails till early next year when I return from the states, maybe you should hook up with that other new guy Hot Rod

    Just worked out how to post the plan. Phone camera pic of my computer screen, bodgey but it'll give you the idea

    Rev 4.jpg
    Last edited by emu26; 12-03-2008 at 01:15 AM.

  17. #17
    mtbr member
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    You could do a printscreen and save it as a jpeg

    Lets see if this post goes in the right place

  18. #18
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    Thanks Emu for a great write up and help so far this is a really stellar thread.

  19. #19
    A waste of time it is is
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    }SkOrPn--7 thanks mate, parts list and suppliers as requested

    hyperlinks are to suppliers

    Battery - 14.8v 4.8Ah Li-Ion protected

    Driver - MaxFlex3 with the following settings
    - Current 1200mA
    - Low Bat warning @ 13.5v
    - Mid Bat warning @ 14.0v
    - Warning indication Flash through main LEDs
    - Duomode selected @ factory levels

    LEDs - 3 Cree MC-E M bin WG tint
    - wired as 2 parallel strings of 6 die @600mA each

    Optics - Cree XR-E XLSL-7090-247
    - 2 8* and 1 25*

    Connector - 2.5mm DC In line jacks

    Wire - internal 7 x .20 PTFE
    - to connector ? Just some scrap twin I had

    Aluminium – 40 x 40mm 6061(?) solid bar

  20. #20
    mtbr member
    Reputation: Pitto's Avatar
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    major bit of DIY milling there. a sprial milling cutter used with the cross slide vise would may have sped things up. still a top effort.

  21. #21
    Lets RIDE!
    Reputation: Jim Z in VT's Avatar
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    You built that housing with just a chopsaw, drill press and some hand tools!?! That's awesome

    JZ
    It's not about speed, it's about lack of control.

  22. #22
    A waste of time it is is
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    Thanks heaps Jim, but I think Aaron has taken it to the next level
    http://forums.mtbr.com/showthread.ph...73#post5158873

    Don't know if I should hang my head in shame at my comparitively slopy work or step up to the plate and start the companion helmet version

  23. #23
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    No shame needed it is a brilliant build with the tools available

    Though aarons is very nice too .

    With what you have learnt the next one will be even betterer

  24. #24
    aka RossC
    Reputation: ocean breathes salty's Avatar
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    Quote Originally Posted by emu26

    Don't know if I should hang my head in shame at my comparitively slopy work or step up to the plate and start the companion helmet version
    Aaron's router bit in combination with your shiny new cross slide vice should be just the trick to perfect your next build. You have to step up

  25. #25
    A waste of time it is is
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    Quote Originally Posted by ocean breathes salty
    Aaron's router bit in combination with your shiny new cross slide vice should be just the trick to perfect your next build. You have to step up
    Unfortunately for my family, garage floor and bank balance, that was always going to be the right answer

  26. #26
    A waste of time it is is
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    Can't believe this over two years old and I've barely used it.

    Improvements are on the way
    Some bar stock, 3 MC-e's and a Maxflex 3-swarth.jpg

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