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Old 04-14-2010, 11:32 PM #1
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Default PHR Laser build

I figured this was the right area to post..Since I'm "modifying" a flashlight.

First, I'm going to log my process through out this thread,posting images as I go.

First, I spent 12 dollars on a 2AA Maglite. This is NOT a LED mag, it wad a tiny, but bright and very hot filament bulb. My first laser designed i desided sucked. So I took on a risk of breaking my laser, by modding it. To start, I used a 1/2" spade bit and drilled the WHOLE lens out. Plastic and 1cm of metal almost. I'm going to mount my PHR inside a metal bushing I got for 4 dollars at Gemmens (hardware store that only exists in my city). AND! The actual maglite case it self makes contact with this metal bushing, so I have both bushing AND flashlight metal as a heatsink. I plan to make a better heat conduction using thermal paste on metal surfaces. So here are my 'in progress' pictures.
Selection of bushings and my PHR (flexdrive)

Drilled with spade bit...Some plastic near the top still (blue)

Trial fit 1

Trial fit 2

The battery end...I hacked the original out, making my own connections.


As said, I'll add more pictures as I go. I like the looks of this MUCH more than my original design! I like the looks of it so far personally...Think i picked a nice choice of host, It's not a black flashlight..its a blue-black-silver.


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Old 04-14-2010, 11:50 PM #2
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Default Re: PHR Laser build

looks nice! dont forget to post pics of the completed build.

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Also, would a crap-load of evenly-wound aluminum duct tape work for heatsinking around the Aixiz module?
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Old 04-14-2010, 11:53 PM #3
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Default Re: PHR Laser build

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Originally Posted by laserboystuart View Post
looks nice! dont forget to post pics of the completed build.

stuart
It may take till next week...I drilled a hole and saw it was hard for a button. So now that's going to be a indicator. However! This flashlight was made with a "Spare light in the tailcap" so actually! I can make the tailcap have a toggle push button. Doing so will require a online order from newark...But I find this probably the best way to make a nice laser. The only other way, which will be a tad harder, is to try to make it so the cap will turn it on/off with a slight twist..

Actually nevermind! I'm going to have it like the original on/off, You twist it till it goes on, untwist it a tad for off. So i might get it done by friday.
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Old 04-15-2010, 12:05 AM #4
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Default Re: PHR Laser build

go at your own pace, its better to take 2 weeks to do something than rush everything in 1 day.

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Also, would a crap-load of evenly-wound aluminum duct tape work for heatsinking around the Aixiz module?
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Old 04-15-2010, 01:30 AM #5
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Default Re: PHR Laser build

This is true but sadly I cant help the fact that I think of ideas too fast, and then put them into play.

Whats left:
Wire it up. Will i do it today? maybe. I do have thin thin wire..so..it's a tight fit!

I pressed the module (with heatsink grease all over it) into the bushing. The bushing slides in..and if you look, I got a LED

How it turns on: Same design as the old way. The more you twist it, the closer the contacts get, and eventually boom! you make contact with the +3V and it goes on. This is how the flashlight originally worked, but in reverse. I ran low on room so i had no choice but to have it stick out a little bit, to give room for wires.


My question to anyone:

Do you think it looks fine? I can press the diode back out..and Bench grind the bushing so it angles from the flashlight body to the laser, instead of just a simple cylinder with 90 degree angles.
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Old 04-15-2010, 01:55 AM #6
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Default Re: PHR Laser build

I think it looks pretty sweet as is, but i have to admit i would like it more pressed in a bit.
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Old 04-15-2010, 02:11 AM #7
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Default Re: PHR Laser build

Well the issue is i cant...This flashlight body has litterly no room to fit this. The board is hitting the 1mm thick plastic plate over the battery. And this is the flex board, rather smallest you get. I can not make it go in farther and the laser was pressed up to its focusing ring.

So sorry, It cannot be done because there's simply no room! But..Still isnt half bad. I think it may look better to make the metal bushing black...
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Old 04-15-2010, 02:18 AM #8
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Default Re: PHR Laser build

It still looks awesome! Lets see some burning videos!
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Old 04-15-2010, 03:09 AM #9
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Default Re: PHR Laser build

Finally wired it up...


Only issue is like i said, the bushing SLIDES in. I need to add foil to give it friction. Right now it slides so it isnt turning on. when i hold the front (as seen in pic) it works. Simple fix I just happy it works!!! It does burn because I done that awhile back 120mA feed.
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Old 04-15-2010, 03:19 AM #10
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Default Re: PHR Laser build

I was about to say your pic wasn't working, but it just showed up after a couple minutes... wierd. The LED indicator makes it look so much cooler! awesome laser!
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Old 04-15-2010, 03:20 AM #11
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Default Re: PHR Laser build

I'm trying to decide if I should put foil around the metal bushing so it stays in, or leave it. Right now, to turn on the laser, you push on the metal bushing like a momentary button However...if i want longer runs.....How long can I run a PHR diode in this thing?
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Old 04-15-2010, 03:26 AM #12
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Default Re: PHR Laser build

With that heatsink... Probably atleast 2 minutes. You should be able to run it until the heatsink starts to get warm. I never keep a laser on after i feel a noticable difference in heat...
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Old 04-15-2010, 03:42 AM #13
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Default Re: PHR Laser build

Looks good. LED is a nice touch.
Thermal adhesive would be better then foil. I personally would grind an angle on the bushing.
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Old 04-15-2010, 09:56 AM #14
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Default Re: PHR Laser build

yes i agree.. very nice host/heatsink and the led is a nice little touch to make your build look a bit smarter.

IMO i would get a tailswitch for the maglite so that its got a nice twist-on, twist-off. here's one for you : AA MINI MAGLITE TAIL CAP SWITCH ON OFF SWITCH NITE IZE on eBay (end time 20-Apr-10 04:18:53 BST)

very smart switches indeed.

oh and by the way.. congrats on the build!

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Also, would a crap-load of evenly-wound aluminum duct tape work for heatsinking around the Aixiz module?
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Old 04-15-2010, 07:17 PM #15
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Default Re: PHR Laser build

I think it's a cool build. LED is, as has been said, a really nice touch. Maybe you can match the LED to your laser colour too? Blue for BR, red for red, etc... ?

I have to say that I think the best finds are those bushings! Is the Aixiz a press fit or is it a little loose? I've found Aixiz to vary in diameter, (just tolerancing. Nothing outrageous), but a, 'shop find', to fit them, even roughly, is a buck saver! They gotta be cheap, right? The only thing that would concern me is the material. If they are steel, (or similar), the heatsinking may not be as good as the custom Aluminium ones. Great find none-the-less. Got a link to them?

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Old 04-15-2010, 07:24 PM #16
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Default Re: PHR Laser build

Are you sure that switch on/off will fit in this? This is NOT a LED maglite. it had a 2mm wide,4mm long filament bulb...

Morgan, Yes I can do a blue LED as soon as I get one. My Green laser (rayfoss) is a blue LED...

This bushing would never fit it. I drilled it out with a drillbit that came to like 0.487 inches or something, wouldnt fit. So i angle the module to grind the sides more and yes, eventually it fit. I found out later, (they are a LOT longer) the next size up was the same fit for the module X_X But they have some that are like 2.5 inches long! Not sure if theres any diodes out there where you need such a large thing..but you never know. I think if i read correct, these are Steel zinc-plated bushings..NOT aluminum.

Oh, and it did slide in hard but stick out 3mm, so the last 3mm i had to press it. The first part though did require pushing but it was done by hand. I also covered it in thermal grease.

Marked it..Grinded it with powerdrill + bench grinder..Now to smooth / shine the metal and install.


Rounded hehe...Polished to a shine with a dremel (Rubber?) green wheel...
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