Cree Dive HeadLamp Attempt #2

[scubamike]

My second attempt in modifying a headlamp with new Cree Emitters. My first attempt resulting in partial failure. More like complete failure... but I guess I have learned from my previous mistakes and have started trying to do it again.

Parts
1 x Pelican 2600 Headlamp
3 x Cree Emitters (I have 2 x P4 emitters and 1xQ5 Emitter)
1 x Tri-Cree Reflector. (Awesome throw, perfect center)
3 x 800mA drivers

Right now I am missing a round heatsink. I have been looking for it and have not been able to find one that will fit and fit my purpose. It seems the only way to get one is to get someone with a lathe to create one for me. If anybody have access to a lathe, please let me know.

I am basically looking for a 47mm aluminum or copper in diameter round disc and 20mm in height.

Without a heatsink the leds will not last 10 minutes at 800mA. I have been thinking even using 500mA to keep it cooler. But that will not get me 200+ lumens which is my primary goal.

I will post more information and pictures once I find all the parts and start soldering the leds.

[mitsuguy]

what about modifiying like an older pentium 4 heatsink? seems like you could take a dremel or grinder to one and make it work...

[Reg]

This looks great...Maybe use some Artic Silver as well to help with the heat transfer to the heatsink.

BTW how did you end up getting the reflector out of the pelican?

[Theepdinker]

scubamike,
Take exact measurements of what you need.
I'll turn one up for you at material cost + USPS to your door.

Theep

[scubamike]

Originally Posted by mitsuguy

what about modifiying like an older pentium 4 heatsink? seems like you could take a dremel or grinder to one and make it work...

I tried to use the dremel on it.. but it will be almost impossible to get what I want by doing it. Cutting aluminum was harder than I expected.. I even tried griding copper pennies.

Originally Posted by Reg

This looks great...Maybe use some Artic Silver as well to help with the heat transfer to the heatsink.

BTW how did you end up getting the reflector out of the pelican?

BRUTE FORCE. I had already decided I will break the reflector. So I took pliers and decided to yanked it as hard as I could. Look and behold.. the entire piece came out clean.

I will use heatsink glue to attach the leds. Heat is one of my main concerns but I got 1-2 ideas more to keep the LEDs cool.

From my previous mod of the UK Q40 light...If the light is underwater it will not break. Water is an excellent keeping the led cool. Even with a plastic enclosure. It was only when I forgot to turn off the light in the surface that it broke.

Originally Posted by Theepdinker

scubamike,
Take exact measurements of what you need.
I'll turn one up for you at material cost + USPS to your door.
Theep

THAT WOULD BE AWESOME!!!!!!!. THanks.. I will send the dimensions once I get my digital caliper.. (1 week from now.)

[kancho]

Actually try some Ram Sinks.. THey are small and you might able to fit few of them. THey are cheap..

[scubamike]

UPDATE:

First of all I would like to thank Theepdinker for making this project possible and for answering all my questions. You are the bestEST!!.

The project used 3 drivers. One driver per LED @ ~800ah each. Which I believe produces around 90-100 lumens each. The headlight is powered by 4 X 2600mAh rechargeable batteries.

I suck at soldering!!!!.

I believe the light outputs is around 180-200 lumens. It's hard to tell the only way I have to compare is another light that's rated at 150lumens. And the headlight is a lot brighter.

In the pictures. The right spot is from a Rexlight with a 14000 battery. Which I believe is about 120 lumens. Manufacturer rates it at 150 lumes. The left spot is the modded Pelican light. It's not so noticeable in the picture..if anybody know how I should take picture and what setting to reflect the brightest level. Please let me know.

The biggest issue right now is HEAT. I will need to test this to know what's gonna happen. My last light died because I forgot to shut it at the surface. :-(

[cummings66]

Keep plugging away...

[scubamike]

I have been testing the headlamp for the last week or so and I had some mix feelings about it. I have purchased new 2900mAh batteries and have been running the headlamp in a bucket of water.

Initially, the light would ran for 30 minutes and then it would gradually become dimmer. After about 1 hour and 30 minutes, you can look directly at the reflector. I tested this with batteries rated at 2300mAh (real rating).

The headlamp was extremely bright the first few days. But it seems, that now is a lot dimmer. It's very hard to tell when you dont have a measuring device. I think the led degraded to maybe 160-170 lumens.

There is a 2 inch gap between the heatsink and the plastic body. I tried filling it up with aluminum wrap to get as much contact to the body as possible. The heatsink gets really hot. Not enough to burn, but I guess too hot for the LED. I dont think there is any other way for me to reduce the heat.

[MadDiver]

Where did you find the LED drivers and the Tri-Cree Reflector ?

I'm trying to make a new 3 led head for my Green Force light.