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Old 12-23-2016, 09:38 PM #1
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Default 16x 405 build in Copper Pen host

Hi Guys I thought Id just post a few pics of a new build, I just completed for a member here. It might give some of you an idea of how I make my pen builds and help those of you who may have a pen host from sinner lying around.

The host is made of pure copper and the 12 mm hole is actually a little smaller than 12 mm making it hard to press the diode in. This makes for exceptional heat transfer though, once you get it in... When trying this make sure you use, thermal paste (which also acts as a lubricant), a big vice and 2 blocks of sacrificial aluminium; one on either end of the laser and diode module respectively. You will mark the surface of the aluminium as you will have to press very hard, but it will protect the host. It will only be possible to press the module flush with the host, so you can use an aixiz metal focus ring, lined up in front of the module to press it the rest of the way. I only pushed it in a couple of extra mms.

Due to a shortage of drivers I ended up buying a completed module with a mini X-boost from DTR, so I dont have any pictures of showing how to set the current. In this case, DTR only had drivers with a fixed output of 520 mA anyway.

In the next image two part epoxy was used to strengthen the connection between the diode module and the driver. As you know the driver is soldered directly to the pins, this means it can move easily as the diode pins are very thin. Due to space restrictions in most pen builds, this is the way the driver is usually setup and this means the spring is attached directly to the driver. As such the battery pushes on the driver and so you dont want it bending away damaging the pins, or creating a short circuit. Sorry that the first few pics aren't very high quality, but they were taken on a phone in the basement.



You can also see how I picked up the negative, by drilling into the module, pressing a brass nail into the hole and soldering the negative wire from the Bat (-) on the driver to it.

The next three pictures show the addition of the spring and isolation of the driver from possible shorts with the inside of the host.





Here is the finished laser with polishing. The 10440 battery shown is the one used in the host and gives an idea of the actual size of the laser.




And we wouldn't be complete without a beam shot and at this time of year we have the compulsory shot with the Christmas tree!



The laser was metered on my Ophir head and outputs 844 mW @ 520 mA.

Thanks for reading and a merry Christmas to you all.


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Old 12-23-2016, 09:49 PM #2
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Default Re: 16x 405 build in Copper Pen host

Nice build!! What does it put out? Boost driver at 520mA?
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Old 12-23-2016, 10:05 PM #3
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Default Re: 16x 405 build in Copper Pen host

Great looking build! A very nice Christmas present to yourself!
All that polished copper and brass seems to fit right in during the holiday season.
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Old 12-23-2016, 10:11 PM #4
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Default Re: 16x 405 build in Copper Pen host

Quote:
Originally Posted by 10fenny View Post
Nice build!! What does it put out? Boost driver at 520mA?
Sorry forgot to mention that, the max I saw on my Ophir was 844 mW @ 520 mA. Will update the post in a mo.

Quote:
Originally Posted by BowtieGuy View Post
Great looking build! A very nice Christmas present to yourself!
All that polished copper and brass seems to fit right in during the holiday season.
Thanks it wasn't for me though! I made it as a custom build for someone.
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Old 12-23-2016, 10:43 PM #5
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Default Re: 16x 405 build in Copper Pen host

Hi G,
Awesome build and those hosts are great and when polished you need sunglasses to look at them. I have 4 of Sinners full copper pens in storage 2 of those will be 520 builds low power. Keep up the great work buddy love to see your work.

Rich Happy Holidays >>>>
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Old 12-23-2016, 11:05 PM #6
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Default Re: 16x 405 build in Copper Pen host

Beautiful build Anthony and I'm sure the customer will be very happy too.

Merry Christmas to you too my friend.

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Old 12-24-2016, 12:35 AM #7
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Default Re: 16x 405 build in Copper Pen host

Awesome
Very nicely polished
If only it didn't turn brown later, I wish they stayed looking shinny.

Nice build good to see a new thread,
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Old 12-24-2016, 05:55 AM #8
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Default Re: 16x 405 build in Copper Pen host

That copper is really looking nice. Somebody will enjoy it and hopefully not drop it. Sanwu says this type of copper dents easily. Copper is soft anyways.
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Old 12-24-2016, 02:11 PM #9
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Default Re: 16x 405 build in Copper Pen host

Quote:
Originally Posted by Lifetime17 View Post
Hi G,
Awesome build and those hosts are great and when polished you need sunglasses to look at them. I have 4 of Sinners full copper pens in storage 2 of those will be 520 builds low power. Keep up the great work buddy love to see your work.

Rich Happy Holidays >>>>
Quote:
Originally Posted by RB astro View Post
Beautiful build Anthony and I'm sure the customer will be very happy too.

Merry Christmas to you too my friend.

RB

Thanks to both of you!

Quote:
Originally Posted by badboybilly View Post
Awesome
Very nicely polished
If only it didn't turn brown later, I wish they stayed looking shinny.

Nice build good to see a new thread,
Its not that bad, its already polished so it would just need a quick buff with eg some Autosol metal polish paste. Takes a couple of mins and its as good as new again. Did this whilst building it.
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100mW 405 PHR
700mW 405

2W 445 C6--link--
+2.3W 445 --link--
+2.5W 445 --link--

190mW 450 --link--
15mW 510nm
5mW 532 --link--
25mW 532 --link--

520mW 638 --link--
1W 638

250mW 650
250mW 780

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Poppas mod 3A --link--
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Last edited by grainde; 12-24-2016 at 02:12 PM.
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Old 12-24-2016, 02:59 PM #10
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Default Re: 16x 405 build in Copper Pen host

Wow, that's one good looking little laser. Little pocket burner. Bet the customer will be over joyed to get that guy! She sure is a beauty that laser gets two drools!
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Old 12-24-2016, 04:49 PM #11
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Default Re: 16x 405 build in Copper Pen host

Very nice, excellent photo's too. Thank you for sharing.
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Old 12-25-2016, 09:13 PM #12
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Default Re: 16x 405 build in Copper Pen host

Thanks Bob and Alaskan, I hope you both had a great Christmas!
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Old 12-26-2016, 12:16 AM #13
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Default Re: 16x 405 build in Copper Pen host

im partial to rubbing my copper down with ketchup... but whatever floats your boat :P awesome build!
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Old 12-26-2016, 09:31 AM #14
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Default Re: 16x 405 build in Copper Pen host

Excellent, now I don't have to take it to pieces when it arrives. Probably for the better
Thanks for sharing and can't wait until this little guy gets here!

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Old 12-27-2016, 10:49 AM #15
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Default Re: 16x 405 build in Copper Pen host

Really nice build and you are not kidding about how tight the fit is. Also good on stabilizing with the epoxy. That's something I tend to do quite a bit also to make sure there's no way the assembly could touch the inside walls of the build.
Ketchup? Are you kidding or not?
Merry Christmas and a Happy new year G
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Old 12-27-2016, 11:14 AM #16
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Default Re: 16x 405 build in Copper Pen host

Quote:
Originally Posted by Euphonious Nonsense View Post
Excellent, now I don't have to take it to pieces when it arrives. Probably for the better
Thanks for sharing and can't wait until this little guy gets here!


Quote:
Originally Posted by Pman View Post
Really nice build and you are not kidding about how tight the fit is. Also good on stabilizing with the epoxy. That's something I tend to do quite a bit also to make sure there's no way the assembly could touch the inside walls of the build.
Ketchup? Are you kidding or not?
Merry Christmas and a Happy new year G
I think this was a serious suggestion, Ketchup contains vinegar which will remove the copper oxide. Unfortunately though Im pretty sure this will ruin the polishing. This is why I recommend the polishing paste to restore the final finish.

BTW I use lemon juice and salt to clean oxidised copper and free it from the oxide - this also works for silver oxide too. This is very quick and effective and similar to the ketchup method.
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100mW 405 PHR
700mW 405

2W 445 C6--link--
+2.3W 445 --link--
+2.5W 445 --link--

190mW 450 --link--
15mW 510nm
5mW 532 --link--
25mW 532 --link--

520mW 638 --link--
1W 638

250mW 650
250mW 780

3000 Lm C8 MTG2 @ 6 A!
Poppas mod 3A --link--
Sipik 98 Cu pill/star mod --link--

Last edited by grainde; 12-27-2016 at 11:15 AM.
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