New Style Dorcy Jr Build

Wow it's been a loooong night -.- ...

But I have great news I finished my Dorcy Jr red build ! And yes it's the new style Dorcy Jr ! O_O. Honestly I'm suprised I did it this was an EXTREMELY tight build, and took a lot to get working. But it was worth it in the end and I learned a ton from doing it so that to me was a big + . Anyways Here are some specs for the whole thing:

AixiZ module
Flexdrive v5 @ 210 mA
AixiZ acrylic lens

Custom heatsink - Dimensions :

OD - 24mm then tapers down to 23.89mm
ID - 11.8mm then tapers down to 11.6mm
Length - 18.6mm

The only thing I regret about this heatsink is not asking the machinist when I gave him the dimensions to make a set screw -.- so the aixiZ module is pretty loose for a heatsink but I'm sure some members will make a polished up version of mine soon enough haha. I would really rather not take it apart but if someone absolutely needs pics then it's a sacrafice for the greater good IMO haha .

Now for the beamshots ! BEEEOOOM !

I actually didn't use the flat piece in this first pic just hallowed out the pill.


Let me know what you think !

Very nice build we've all been puzzling how to get the heatsink to work, if you don't mind me asking how did you manage to get it to stay in place?

And also a threading set to tap a set screw wouldn't be too difficult to do and not very expensive either.

Very nice build btw.

The heatsink was easy it was the tapering that little bit that helped a lot I also had him make it a very very tiny big bigger so you couldn't press it in with your hands I just used a little vice grip action but nothing even close to force haha so it was a tight fit but comfortable too

threading set hmm ? sounds very interesting ... I'll have to look into it ! Thanks for the heads up !

Gotto love copper. Should be soft enough for tapping be careful with your finger though.

I agree ! Copper is the best. I just wish I would have polished it up a little before .....
Maybe I'll do it anyway .

I believe this is the kind of thing you are looking for

40-Piece Tap and Die Set : Screwdriver Accessories : Maplin

Although I assume your not in the UK so just do a similar search.

Edit, sorry double post

Very good ! Thanks ! I don't have work tomorrow so I'll go look around the local stores and see what's up.

You could use a dremmel to shine that puppy up... just a thought.

Really ? I thought about some fine sandpaper but I wasn't sure how that would look ... should I use the dremel sander ? Or the little brush ?

EzPk0970 said:

Really ? I thought about some fine sandpaper but I wasn't sure how that would look ... should I use the dremel sander ? Or the little brush ?

Click to expand...

I wouldn't sand it because the very fine taper on the heat-sink would be affected, assuming that the machinist has done a good job at keeping the surface smooth, using a fine brush and some polish on the dremal should work.

Dremmels have polishing wheel adapters. I know you can shine that bad boy to a mirror.

Since you already have a machinist and host with dimensions I would build several of these. Then move on to the next. Seems a shame to only do one or two don't you think?

Yes but the way you have to assemble it to make it all fit is a bit schotty. it tapers down so what i did was i soldered the driver to the diode and put it all the way down in the heatsink until it wouldnt move then soldered wires to the flexdrive to the inside of the pill, puished it back up so you could freely rotate the heatsink but not the module then pressed everything in. The handle isn't even all the way in honestly... It's a smidge past the O-ring so its stirdy but not all the way in. There just isnt enough room for everything. But I have an idea maybe I'll try just to see if it works

Great job on making the first new style Dorcy Jr, even if it isn't an ideal way to assemble it.

Ya I figured it's not going to be perfect but the dimensions should help at least a little bit . I'm hopefully going to meet up with scopeguy20 and were going to go see daguin so I'm really looking forward to that and I bet he can look at it and give me some feedback on it.