'Making the Nightmaster or P60 drop-in' by Jinks.

Nominate your favourite 'informative' posts to place here, and links links to suppliers too.
Locked
PESCA

'Making the Nightmaster or P60 drop-in' by Jinks.

Post by PESCA » 24 Mar 2013, 08:20

Had a go at making my own Oslon IR drop-in to fit my nightmaster torch the other night, thought I'd share the process with you. The finished pill can also be used in any P60 host (solarforce l2, ultrafire 501, 502 etc)

Started off with an empty P60 heatsink
Image
These can be purchased from here
http://www.cnqualitygoods.com/goods.php?id=1400

The oslon star is to big to fit into the recess on the heatsink, so I filed the top of the heatsink off leaving a bigger flat surface
Image

Also the star needs to be filed down to fit the heatsink, taking care not to file into the contact pads. Two of the recesses on the star need to be filed deeper to allow the wires to pass through when fitted to the heatsink
Image

I used Artic Alumina Thermal Adhesive to secure the star to the heatsink
Image

I decided to use a linear type driver as I wanted to run the oslon at full power from a single 18650 battery (I find the nightmaster a bit cumbersome fitted on top of the scope with 2 batteries)
I only had 1400ma drivers to hand, so I removed one of the 7135 chips to make a 1050ma driver (Each chip is rated at 350ma)
Image
These drivers are available rated at 1050ma from here
http://dx.com/p/17mm-1050ma-single-mode ... -5v-127687

Wires soldered to driver
Image

Driver fitted and soldered into heatsink and contact spring fitted
Image

Link for Springs http://www.cnqualitygoods.com/goods.php?id=1127

Wires soldered to star
Image

It is important to fit an insulating washer over the star to prevent contacts from shorting when the pill is screwed into the nightmaster housing or p60 reflector.
http://www.intl-outdoor.com/cree-xre-le ... p-479.html

Finished pill fitted into nightmaster
Image
Image

Locked