Sunday, June 24, 2007

MAG 3D SSC P4 (1050mA)

ok, a lot of people have already done this so I'll keep the words short and let the pics do the talking (sorry they're a bit grainy)...
Here's an SSC P4 MAG 3D mod (using the AMC7135 1050mA circuit from DX):
SSC P4 epoxied to Litemania heatsink (with Artic Alumina Adhesive):

Now add clear epoxy to the outer rim with Glow in the Dark powder:

Here's a glow shot:

Wire traces soldered to the AMC7135 circuit board (note both jumpers bridged to give 1050mA):

Wire traces soldered to led through holes in heatsink:

Bottom view:

Top view:

Stock MAG 3D:

Stock MAG 3D incandescent bulb:

Removing the rubber switch cover:

Using allen key to remove switch assembly:

Dropping switch assembly out through rear:

All MAG 3D parts disassembled:

Removing bulb holder mechanism from switch assembly:

Removing -ve contact from switch assembly:

Removing switch barrel (+ve) from assembly:

Soldered wire traces onto both +ve & -ve parts:

Insert barrel part into main switch assembly (+ve):

Then insert the -ve part:

Slide switch assembly back into MAG body and tighten switch, notice no cutting of the switch assembly:

Solder -ve & +ve wires to the circuit board:

Insulate the circuit board (I used electrical tape, you could also hotglue the circuit to the underside of the heatsink however it may require cutting of the switch assembly:

Looking into the barrel:

All wires and circuit inside the MAG body:

A snug fit:

Now with a heap of thermal transfer paste... and yes, the heatsink does go all the way in... I just took the pic before having all the paste squeeze out everywhere.

Now to mod the reflector ... this is the only non-reversable part of my mod, but MAG reflectors are cheap and easily replaceable. Trim the cam portion off with any useful tool.

Install the modded reflector:

With the head back on and batteries loaded:

Beam shot at approx 1m:

Another shot:

From the front:

A Closer look:

And now a nice GLOW....

One last pic to finish it off...

Thanks to Nereus and all the other helpful threads/tutorials on how to mod a MAG. I'll post some comparisons between this and my MAG 4D SSC P4 with 800mA circuit (also from DX) as well as a stock 3D.


In order from left to right: MAG 3D SSC P4 (1050ma), MAG 4D SSC P4 (800ma), MAG 3D stock.

MAG 3D SSC P4 (1050ma), MAG 4D SSC P4 (800ma) (-2 exp)

Again: (0 exp)

In the dark:

Side by side:

Business end of the MAG 4D SSC P4:

And now the MAG 3D SSC P4:

Monday, June 11, 2007

A New Host for my trusty Luxeon 5W bike light

It's been a while since I first built my Luxeon 5W bike light. I was very impressed with it although it looked a bit like a hydra with it's heatsink fins...

I'd always intended to modify it and put into a better looking host and that it just what I did last night.

Specs: 5W Luxeon, 3021 BuckPuck, 4x 18650 in series.

Here it is:

If you want to see more pics keep scrolling down .

Here is what the original cap looks like... the pepper one has had the hole cut into it. This was by far the hardest thing for me to do. I used my cheap dremel like tool to cut a rough hole in the center and then ground it until I had widened it enough.

1)Bottom of the pepper shaker
2)Inside view
3)3021 buck puck
4)Wiring and switch
5)Switch and wiring from the back
6)3021 inside. Lots of room
7)Compared to an 18650 cell

Aluminium reflector from DX with threads removed.

I cut my own glass lens from a cheap $2 photo frame and hot glued into the lid. Then the Reflector was hotglued into place.

I fashioned a U style bracket from aluminium bar so that it would be a tight squeeze. It was too tight. I had to do a lot of filing but I guess that means for better contact on the edges.

The 3021 buckpuck fit's nicely into this bracket. The orange wire you see in the image below is just to help me pull the bracket out (it's that tight a fit).

Front view... here the led looks a bit out of centre.. but it doesn't seem to make much difference to the beam profile. I tried experimenting with moving the reflector around (closer and farther) but it seemed that the best profile was right up against the led.

I've got a scratch on my hand... battle scars.

More pics in case that wasn't enough:

Here together with the battery holder I built:

All dissassembled..

And now some beamshots:

First my hallway:

And now the wall (somethings wrong with my camera settings... too much noise):

The reflector from DX seems to do a good job compared to what I had previously (my camera settings are alot different):

All in all... took around 4 hrs work. I enjoyed most of it.
Now... I have a spare canister and lo and behold... a spare reflector and SSC P4... I wonder...

EDIT: Here's pics of the old 5W light: