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DIY 700+ lumen SSC P7 3D Maglite modding, Lotsa pics!

Discussion in 'Do-It-Yourself & Gear Modifications' started by 3rd_shift, Apr 5, 2008.

  1. 3rd_shift

    3rd_shift Empty Pockets

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    1st of all, here is the problem with a stock 3D Maglite.
    Here it is pictured with a 60 watt outdoor lamp.
    [​IMG]
    Ya kinda get the idea that current flashlight technology needs some help.

    New led = another pictorial ;)
    Seoul semiconductor has done it again with thier latest P7 led.

    Let's break out some tools and have some fun!

    Take off the head tailcap and dump out the batteries.
    [​IMG]

    Take off the switch boot without tearing it up and use a 5/64ths allen wrench to loosen the switch assembly.
    [​IMG]

    Use the same allen key hex wrench to loosen the bulb holder guts.
    [​IMG]

    Dump those out.
    [​IMG]

    Make the switch assembly look something like this.
    [​IMG]

    Make the stock reflector look something like this nice and neat.
    Go ahead and ream out about an additional 2 millimeters from it's apex to make that bigger for this large P7 led.
    [​IMG]

    Heatsink makers; we have a little problem here.
    None of these heatsinks are flat topped for this large led's slug.
    The ideal heatsink would be flat topped and type3 annodized for electrical isolation.
    [​IMG]

    I finally flat topped the h22a bare aluminum unit for this demonstration.
    But we still need to electrically isolate this big and expensive led's (+) bottom from the light's (-) ground. :(
    [​IMG]

    Cree to the rescue.
    I cannibalized an obsolete P2 flux Cree XRE for it's ceramic base to use as a thermally conductive electrical isolator.
    Remove and shave all the guts and cut the corner pass-through contacts off.
    [​IMG]
    [​IMG]

    Mix up some 2 part arctic alumina.
    [​IMG]

    Apply the rigged isolator to the heatsink and bullseye center it.
    [​IMG]

    Do the same with the led on top of that.
    [​IMG]

    Cut a couple of wires like this about 5 inches long.
    [​IMG]

    Preflux the wires and the places where they are getting soldered to with rosin flux.
    [​IMG]

    Wire these into the switch assembly like this nice and neat.
    [​IMG]

    Re-install the switch assembly into the light.
    [​IMG]

    Has the Arctic Alumina adhesive hardened yet?
    Good, we have more work to do with that heatsink.
    Drill 2 more holes carefully like this because the led is too big for the original ones.
    [​IMG]

    Now we can wire up this led heatsink assembly.
    [​IMG]

    Bend and squish the wires into the flashlight a little something like this.
    [​IMG]

    Note:
    The led has a pinhole in one of it's leads.
    That is it's (-)

    Guide the wires into the heatsink noting the led's polarity.
    Apply heatsink grease to the heatsink and push it into the light.
    It went right in this time. :)
    Use a hollow pvc pipe and mallot if needed to drive it in fully without splatting the fragile led.
    [​IMG]

    Bring the wires through like this a little more and preflux them with rosin flux.
    [​IMG]

    Put the light in a gentle vise, or holder and use two hands to position and solder the wires into place.
    [​IMG]

    Okay, load the batteries back in without the tailcap.
    Push the switch to the "on" position and give it a go with a dc ampmeter.
    Here it is with fresh alkalines at 1.72 amps, no problem here. ;)
    [​IMG]

    Again with Nicad D cell batteries at about 2.3 amps.
    Still no issues here either.
    [​IMG]

    This is why the reflector's apex was reamed out bigger earlier.
    The big led and it's "wider stance" wiring made this necessary.
    [​IMG]

    Still, there never was any light hitting the removed part of the apex anyways.
    No harm there.
    [​IMG]

    Remember this?
    [​IMG]

    Now watch this!
    [​IMG]

    60 watt vanity light getting clobbered.
    [​IMG]

    4 26 watt compact flouros at 1600 lumens each getting lit up a bit.
    [​IMG]

    4x100 lumen quad UXOJ binned Luxeon3's totalling about 400 lumens getting owned.
    [​IMG]

    Obsolete Luxeon5 WX1T pushed to near 200 lumens getting beaten bad in every way.
    [​IMG]

    Call the Police or Security!
    Stock Magcharger getting clobbered.
    [​IMG]

    Happy modding!! :D
     
    mikel81 likes this.
  2. mr.squatch

    mr.squatch Empty Pockets

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    The modding world wouldnt be the same without 3rd shift walk-thrus. Learned a lot over the months from em, even managed to mod a few of my own lights. O0 Thanks a lot buddy, keep up the good work


    g
     
  3. karlito

    karlito Loaded Pockets

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    About how much would all of the ingredients for this mod cost? I've never modded a light before and this looks interesting. Wondering about the cost - empty pockets :sigh:
     
  4. 3rd_shift

    3rd_shift Empty Pockets

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    I just charged some nimh D cell rechargeable batteries a little while a go and pulled them out of the fridge.
    They measure 3.3 amps cold inside the light.

    See that staircase?
    [img width=600 height=450]http://img.photobucket.com/albums/v313/3rd_shift/SANY0140.jpg[/img]

    This one.
    [img width=600 height=450]http://img.photobucket.com/albums/v313/3rd_shift/SANY0141.jpg[/img]

    See that new condo?
    [img width=600 height=450]http://img.photobucket.com/albums/v313/3rd_shift/SANY0143.jpg[/img]

    Look inside.
    [img width=600 height=450]http://img.photobucket.com/albums/v313/3rd_shift/SANY0144.jpg[/img]

    2 55 watt headlights versus a Seoul P7.
    [img width=600 height=450]http://img.photobucket.com/albums/v313/3rd_shift/SANY0145.jpg[/img]

    What's inside that pickup truck?
    [img width=600 height=450]http://img.photobucket.com/albums/v313/3rd_shift/SANY0146.jpg[/img]

    Nothing this time. ;)
    [img width=600 height=450]http://img.photobucket.com/albums/v313/3rd_shift/SANY0147.jpg[/img]

    See that building?
    [img width=600 height=450]http://img.photobucket.com/albums/v313/3rd_shift/SANY0150.jpg[/img]

    This building.
    [img width=600 height=450]http://img.photobucket.com/albums/v313/3rd_shift/SANY0151.jpg[/img]

    See that cat?
    [img width=600 height=450]http://img.photobucket.com/albums/v313/3rd_shift/SANY0153.jpg[/img]

    This kitty.
    [img width=600 height=450]http://img.photobucket.com/albums/v313/3rd_shift/SANY0154.jpg[/img]

    Well lit staircase.
    [img width=600 height=450]http://img.photobucket.com/albums/v313/3rd_shift/SANY0155.jpg[/img]

    More light added. ;)
    [img width=600 height=450]http://img.photobucket.com/albums/v313/3rd_shift/SANY0156.jpg[/img]

    Video of a walk outside with fancy flashlight.
    http://smg.photobucket.com/albums/v313/3rd_shift/?action=view&current=SANY0142.flv

    A walk into the forest.
    http://smg.photobucket.com/albums/v313/3rd_shift/?action=view&current=SANY0148.flv

    A walk back out of the forest.
    http://smg.photobucket.com/albums/v313/3rd_shift/?action=view&current=SANY0149.flv

    Back on apartment property.
    http://smg.photobucket.com/albums/v313/3rd_shift/?action=view&current=SANY0152.flv
     
  5. illusion

    illusion Loaded Pockets

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    Nice mod! O0
     
  6. tinyblob

    tinyblob Loaded Pockets

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    Great work! I'm really looking forward to seeing how the P7 emitter gets used, there are going to be a lot of very bright lights!

    I can't say i condone the use of that poor black cat as a test subject though! I hope it had it's eyes closed!
     
  7. 3rd_shift

    3rd_shift Empty Pockets

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    I had a cat for 21 years.
    If you bring a bright light onto a cat slowly, it will close it's eyes like this one did.
    Notice that it's eyes in this case were shut and not shining back at the camera. ;)

    It should however be noted that led lights are "instant on" and can indeed blind anyone before thier blink reflex can slam eyelids shut.
    Please do not shine this light at anyone's eyes and especially don't turn on this light without warning on someone when they are looking in your direction.
    There were such warnings on led lights far smaller than this a few years ago.
    Those warnings are now more serious with todays brighter 700-900 lumen leds.
    Even just the sidespill left a parts counter guy on my route in Tulsa, Ok seeing spots yesterday.
     
  8. jzmtl

    jzmtl Loaded Pockets

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    I always thought cat (and other noctual animals) don't get bothered by bright light. I've tried to point a laser pointer at eyes of some noctual animals and they don't even blink.

    How well does alkaline last? I try to stay away from rechargeables, too many to manage, and I don't use them that much to justify the cost.
     
  9. 3rd_shift

    3rd_shift Empty Pockets

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    Alkalines are still a good choice for this light.
    Those usually start at 1.5-2.5 amps when new and then level off for a while at 1-1.5 amps allowing the light to stay reasonably cool.
    What other 3D light can run above 300-400 lumens on regular unleaded alkalines?

    Rechargeables are more for security, or showing off in this light's case. ;)
     
  10. mikel81

    mikel81 Loaded Pockets

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    A laser can damage your eyes without even being visible light. You should always wear the proper safety glasses when working with lasers, and NEVER play with children or pets. The damage can happen instantly. I have a 532nm green laser that will pop balloons and melt plastic.
     
  11. karlito

    karlito Loaded Pockets

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    Um anyone?? :popcorn:
     
  12. snidera

    snidera Loaded Pockets

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    IF you have the maglight, the P7 LED is gonna set you back a whopping 25$ or less. The rest of the stuff is probably already around the house.

    ETA: Forgot heat sink..... :brickwall:
     
  13. mikel81

    mikel81 Loaded Pockets

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  14. Edwood

    Edwood Loaded Pockets

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    Very nice tutorial and funny daytime beam shots.

    I think I'll wait until there are some proper P7 heatsink bases to attempt this mod. Otherwise, my M*g61 hotwire will have to do for now.

    -Ed
     
  15. mikel81

    mikel81 Loaded Pockets

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    There are proper heatsinks out. Check CPF user H22a, should be shipping HAIII this week. I ordered 2.



    http://www.candlepowerforums.com/vb/showthread.php?t=160483
     
  16. mikel81

    mikel81 Loaded Pockets

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    :dance:

    @3rd_shift - Thank you for the beautiful tutorial!

    Got my heatsinks the other day, and assembled it last night. This thing is BRIGHT. I would highly reccomend this mod to anyone with basic soldering skills. It was one of the easiest mods, and it is so worth it.
     
  17. mikel81

    mikel81 Loaded Pockets

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    :spotlight:
     
  18. peacefuljeffrey

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    :shocked:

    I think it's the opposite! OMG it pains me to think what might have happened to the retinas of the poor animals you did that to. :(
    Think about it -- the fact that they're nocturnal means that they are more sensitive to light, and their eyes pick up more than ours do!

    Please don't continue to do that!
     
  19. WolfAmmoMan

    WolfAmmoMan Banned

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    ** A good point ! ^^ :shocked:
     
  20. jzmtl

    jzmtl Loaded Pockets

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    I have very unfortunate news, the OP 3rd_shift has passed away.

    http://flashlightnews.net/forum/index.php?topic=943.msg14654#msg14654