First Build-650nm 300mW

So I have begun my first build. I wanted to keep it simple, and since I lack a red laser, I chose this approach. I actually have finished the the electrical assembly and tested it. So far, so good.

I chose as a host a cheap dollar store led flashlight that runs on 3AAA in a sled. It's annodized aluminum, with clicky bottom button. The most troublesome aspect is fitting a heatsink for the diode.

Parts:
650nm 300mW in copper module (DTR)
Mohgasm linear driver set at 378mA (mohgasm)
X-blank battery contact (cajunlasers)
Copper 1/2in heatsink for driver (cajunlasers)
Thick copper pipe connecter for diode/driver heatsink

I plan to use the AAA sled with two 10440s, with dummy in third slot.

I'm currently waiting on a shipment of artic silver thermal paste, as well as 1/4in aluminum heatsinks to continue. Biggest problem I have is sinking the diode module with the DIY copper sink, while keeping it centered. This is due to the inner diameter of the copper "sink" is too big. I plan to try and use the 1/4in Al sinks on the module, and see if i get a snug fit. If not, I'll work something out..

Try using some copper shims to get a tighter fit.
Don't forget to meter your Laser once it is completed..


Jerry

Well, after a few "back to the drawing board" moments, i have finished my first build. I wound up not using the copper pipe fitting, as there just wasn't room. I also cut most of the spring from the tail cap and soldered part of that to the bottom of the contact board.

The hardest part of this build was getting the contact board in correctly. Once that was finally in and secured, i heatsinked the crap out of the driver. After some time experimenting, i finally crammed the driver and module into the top, using thermal paste to attach the module to the host.
Because of the space resrictions, the end result is... well not pretty.

It definatly won't win any awards for looks, but it works. Runs fine off of two 10440 batts.

Thanks Jerry for the advice and for looking. Yes, I do plan to get an LPM.

Chaos, that is one seriously ugly host (in a good way). Congratulations on it! I'm glad it's working well for you. +1 for getting your hands dirty on your own build!

Just my 2 cents, I'd say you over did the heatsinking on the driver, as it doesn't need much at all at that current, and sacrificed the ability for more heatsinking on the module.

It's great to see you making your own. That's what I just love about this hobby. I'd love to see your measured output.

Thanks! It took more than i thought it would to get it done, but i learned from it.

I do agree i went overboard on heatsinking the driver. Right after i slapped the copper sink on i regreted it. I haven't done an actual test, but i ran it ~1 minute before it got mildly warm.

I went with this mainly to get my hands dirty, get some hands on. I've delt with electronic before, the mechanical part is where i lack experience. So i gained some.

That's what this hobby is all about...I got into this specifically to learn the things I've always wanted in my wheelhouse, but haven't learned yet.

Keep up the good work.

CL -- That's where we all started long ago.
Yours looks better than my first attempt with a 50 mW red!
Keep going - - - - - -+1
HMike

Thanks HMike, and I definately shall keep going. I got the bug.

Nice first build! A tip - I also have that same flashlight and there is a washer (can't remember what size it was, currently on vacation so I can't measure it) that fits perfectly on top (not inside) of that flashlight and you can also press the front half of the module into the hole in the middle (Screws up the threads but it's stuck there forever, you need to press it in with a vice). It is the same washer that I used with my first red build (HERE, you can't see it, it is inside the head). I will be home by tomorrow and I will get you the measurements a.s.a.p. (that's if you want them, just PM me). :gj: on your laser! +1 coming your way!

Thanks cube! :beer:

Yeah, i tried to find a washer to do just that. I even tried to screw the module into a washer, but didn't think of useing a vice to press it in. Hmmm, maybe i will do a version 2.

Looking better than my "early" builds that's for sure!

Well done +2 for you.

I finally got some beam shots, though their not the best. I also posted video of some particle trapping, witch is the first thing I did with the laser.

They can be found here: http://laserpointerforums.com/f48/pics-particle-trapping-first-build-81682.html#post1173314

Very nice build Well-done!