Update: I am offering a basic kit for this build! See here:
http://laserpointerforums.com/f39/fs...tml#post558775

This little key chain light at Lowe's is made from a solid piece of brass! It is very heavy duty, but very small.

Here's the host:
Task Force at Lowe's: Mini LED Key Chain Light

I managed to get a FlexDrive inside there for an 803T blu-ray build! (then I made a red build, and then I made a 6X build - 268mW's with my 405-G-1 glass lens mod! (see lens in my signature)

Here are the pictures...


(beam shot with some smoke)








I found that the stock, 'stacked' button cell batteries were not enough to run a FlexDrive...

The answer was to use a 3.6 volt Lithium 10180 battery. Or better yet... the tail cap can be drilled out to fit a 10280!

The 10180 batteries are 90mAh... But the 10280's, are 180 - 200mAh's!

With this in mind, I chose the highest efficiency PHR diode that I could find to keep the current as low as I could and still have good power!

117mW's @ 117mA's!

With a 10280, that should give around a 1 hour run time per charge...

* Here's the batteries: (his site is not updated, but he has the batteries. Just message him)
AW's LiIon Batteries Sales Thread *Part 8* - CPFMarketPlace

* Another good source for the batteries:
AW 10280 Unprotected Rechargeable Lithium Battery

* Here's the charger:
Battery chargers for lithium ion coin cells

For the 10180 fit: I shortened the spring on the tail cap just a little, because the 10180 is just a little longer than the 3 stacked button cells that came with the host.

The only other thing that I did, was to bypass the little button circuit on the stock board to make it a momentary button switch...

It had some kind of little circuit that allowed it to be a constant on / off switch, but this did not work with the FlexDrive, so I just bypassed the circuit...





Notes: Figure a setting of about 130mA's to give (normally) 115mW's of blu-ray with the 803T diode for around a 1 hour run time between charges with the 10280 battery.

For a red, 275mA's still gives me 200mW's using the Sony/Senkat SLD1239JL-54 diode, along with the AR coated acrylic lens that I have linked below. I bought these from flee-bay. (thanks for that Igor)

Considering run time (boost vs buck vs diode used), Igor did some calculations that theoretically should allow using a higher current with a red diode build! Because the red diode takes less voltage, and the driver doesn't have to boost. A 200mW red, should be about the same battery life as a 200mW blu-ray. (I'm guessing about 1/2 hour at this higher current with a 10280)



Here's the lenses for red diodes. You'll get about 10% more power with these (vs AixiZ acrylic), and they fit right into the AixiZ module!:
plastic collimating lens, great deals on Business Industrial on eBay!


Get 20% more power vs AixiZ acrylic using my 'Meredith glass fit for AixiZ' lens modification shown here:
http://laserpointerforums.com/laser_...ad.php?t=22501




For a 6X build - A normal efficiency GGW 6X diode, set at 180mA’s, will give you around 170mW’s. (AixiZ acrylic lens - back opened)
But with my 405-G-1 glass lens modification, you will get at least 26% more power!






Tail cap mod!
I found just enough room in this host for a 10280, by drilling out the tail cap! (thanks for that idea Igor)

Now there is room for a 10280 (180 to 200mAh), which is twice the capacity of a 10180!








Battery tip:
The AW web site where I ordered the 10280's, says 180mAh's, but the batteries say 200mAh's on them!

I thought I would show that it is an easy mod to expose the negative end of the battery edges. This is needed with this build using the longer batteries. Because of the tail cap mod, there is no longer a center spring...









Battery Current Draw - for 3 different builds:
Here are my three different builds and the current draw on fully charged (200mAh) 10280 batteries...



* High efficiency PHR-803T blu-ray set at 117mA's and putting out 117mW's. (AixiZ acrylic) - 175mA's battery current draw.

* Sony/Senkat SLD1239JL-54 red set at 275mA's and putting out 200mW's. (AR coated lens) - 228mA's battery current draw.

* High efficiency (freak) GGW 6X blu-ray set at 183mA's and putting out 215mW's! (AixiZ acrylic) - 288mA's battery current draw. 268mW's using my 405-G-1 glass lens modification!

I'm guessing the 6X build will be 30 minutes run time (or less), but who cares?... 268mW's of blu-ray in a Key Chain build!


Build tip:
Before you complete the build, make sure you check to see if you are getting a voltage reading between the negative end of the battery, and the host! If you are getting any kind of a voltage reading here, then you have not disabled the stock switch circuit good enough...

There is a connection from one edge of the board (which is ground), that goes to the center. This has something to do with the way the little circuit would let the switch be a 'constant on' switch. I found that I needed to 'scrape' through this connection to by-pass the circuit completely...

Otherwise, I got a voltage reading from the negative end of the battery, to the host. Strange... On one of my builds, I actually got a small current draw here, and it would slowly drain the battery. After I did the above 'fix', the problem was solved.






Another build tip:
For a build like this, where your module goes in last with a 'light' press fit, a custom tool is needed to be able to remove the module for diode replacement if ever needed...



The plastic AixiZ nut is not strong enough to to pull out the module. And if you unscrew the head, the wires will twist and destroy the driver connections in this very tight build.

I made this custom tool from solid brass round stock (in case I ever need it), which will work well for Leadlights, and this tiny Key Chain build as well! It is 4" long, for a nice grip.

$23 dollars plus $3 dollars shipping.

The thread size is 9 X 0.5

Here's the site where I bought the tap and die set: (look for 9mm X .5) Thanks for that Kenom!
Tap - http://www.victornet.com/cgi-bin/vic...ps:602,902,604
Die - http://www.victornet.com/cgi-bin/vic...03%2C606%2C599


Use a 7/32 bit for the hole in the tip of the tool... That way you can screw it all the way into the module, and not worry about the tool hitting the diode...

These threads are so fine, that there is pretty much no tolerance. Your piece must be exact before threading. Use a caliper that is accurate to 1/1000th. Then, get your material diameter exactly .361 in., and your good to go for the threading!


It's a good idea to leave an AixiZ module threaded on for protection when storing the tool...
Jay


Micro Blast Key Chain Flashlight Mod! - Must see:
I did a nice little flashlight mod for this key chain too! Check it out!
http://laserpointerforums.com/laser_pointer_forums_3/forum/showthread.php?t=34174








Click here to see my list of projects and tutorials!

o....................mg!

BRILLIANT work Jay.. I am speechless!

EXCELLENTEPRIMOFINE, Jay

I like small....nice build!
Regards rog8811

Nice buildx2.

Thanks for the props guys! Music to my eyes...
Jay

That my friend is sweet!! Absolutely beautiful.

Thanks Ken!

I must confess that it was you who got me wondering when I saw your 'Teenie Burner'... wondering if there could be some way to get a key chain sized build to actually fit a driver. Maybe a FlexDrive with the 10180 (and now, a 10280) battery!
Jay

Well, I'm impressed. You have done an excellent job !

Jay, excellent! Love that idea, because... well, you're walking just a step or two faster than me, on the same path! I just got a sample of a similar host, and was looking for the battery in a rechargeable lithium... thanks for that source link!

8-) 8-) 8-)
DanQ

i have the same light they are very nice nice job jay [smiley=thumbsup.gif]

here is another link to those batteries

http://www.lighthound.com/AW-10180-U...y_p_20-92.html

I've gotta make a trip down to Lowes now.

CURSE YOU RED BARON!!!!!!!

Peace,
dave

OK so here's a little question. How in gods name do you hold that head still while you drill it out? I've got a ton of these teenie burners that I have to drill out. While I can do it, it's lengthy and hard to hold in a vice with a drill.....

Jayrob does it again!
When will you stop making all these incredible builds?

^ NEVAR! *;D



That laser looks awesome!

Hey you guys, thanks for all the great comments!





Dave,
This comment made me laugh out loud!








danq, these are great little rechargeable batteries... But remember that the smaller one is only 90mAh capacity. I think it is just right for this little key chain build with a PHR blu-ray, but for a 6X or a red burner set at 400ish mA's it would not be much capacity. It would work though...
Edit: Now that I have my tail cap drilled out to fit a 200mAh 10280 battery, I've got a red build at 200mW's, and a 6X blu-ray at 268mW's!

I did some searching for a suitable charger, and all I could come up with is the Lithium coin cell charger that I linked in the first post. A normal CR123 charger would put out too much charging current and not be good for the 10280.








Kenom, I can imagine what you mean! Way too small to try to drill it by hand... Needs to be precise. A lathe my friend, is the proper tool for this job...
Jay

The charger!!! http://www.lighthound.com/Nano-Charger_p_21-1283.html ;D just add spacers, and AUTO shut off!! no overcharge!!

heh... ya, tell me about it - I have these little LiPo's about 1cm square x 1mm thick...
10mAh looking for a purpose in LiFe

Yeth, thath twue... if you be a lather -
Lathe On!

Hey I'm hooked on this hobby just like you are! Seems like even if I find a seemingly perfect build, I still want to try and modify something else...

Really, thanks to the awesome FlexDrive by Dr. Lava... For making many host/battery configurations a relatively easy build!





DayOfShadows, thanks for posting that link to another charger. It doesn't say the exact charging specs, but it says something about an automatic circuit to adjust charge current... Nice!





danq, I hope it didn't sound like I was bragging that I have a lathe or something... It's just that for a mod like this, I really can't imagine trying to get it drilled out properly without one.

Man, that little lathe sat in my garage for years! Glad I kept it... now that I'm onto this cool hobby!
Jay

No, no, NO!

sheesh, maybe I'm not using enough emoticons lately - do I seem serious?
...don't answer that seriously!


[pre] [sup] Ib Flogged[/sup][/pre]

Well the charger works for me, might need to meter it buy it seems to charge them just fine, just dont touch the spacers, it hurts :-/ ;D ;D

You just have to make sure that the charger is not charging too fast for the capacity of what ever battery you are charging...

A rule of thumb for any Lithium battery is that it should normally be charged at no more than a 1C charge rate. That means, one times its capacity in mAh. Since this tiny battery is only 90mAh, it should be charge at a rate of no more than 90mA, less than .1A.
Jay

So, I could just ship these to you and you could slap them in your lathe and go to town on them then. It literally takes me upwards of an hour to drill out just one. and sometimes it turns out sideways. I have to take a strap wrench strap that is nylon webbing coated in rubber, wrap it around the head, close it and the rubber in the vice and drill a little until the rubber starts to melt from the heat generated in the aluminum, reseat it after it cools a bit and try again. Over and over.

THATS IT!!! I'M BUYING A LATHE!@$%%^ *grumble*

Wow Ken, I can't believe you even get it to work that way!

Hat's off to you...

I'm sure I could drill a few out for you if you just let me know exactly what you need.

If (when) you get a lathe, make sure to get one with at least 12 inches between the centers. Otherwise, there will not be much room after you put a good size drill bit in there...
Jay