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Old 07-11-2017, 11:21 PM #1
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Default EP's Host Build Guide

It's about time I put this thread together, here's how to assemble my hosts. I'd say it's easy to grasp, and the process is identical for every host I make.

Materials

All are included unless otherwise stated:



Heatsink: The one shown in the image is threaded, however some are not and will require the thermal adhesive (or any adhesive of your choice) to bond to the host body

Thermal adhesive: While it's best to use a thermal adhesive so the host body can be part of the heatsink, the most important factor is mechanical stability. The last thing you want is that heatsink coming loose, so chose your adhesive (I'd recommend epoxy) wisely. Keep in mind that the bonding surfaces will already be roughened and sometimes include machining marks, which is good for the adhesive to latch onto. And saves me from having to treat the surface

Host body: The handle/battery bay of the host

Contact plug: 3D printed with plastic, and therefore insulates the two power lines (positive and negative) from each other. Uses a bolt and a nut, very simple, no soldering required.

Case negative module: Any laser module of your choice with an integrated driver, as long as the amount of batteries meet the input requirement on the driver. The module needs to be case negative, or at least have some sort of case connection. This is very easy to do by just having the negative input of the driver soldered to the case pin on the diode with a very short wire, all internally. I haven't even done this myself, because if you ask DTR nicely he'll do it for you It can be done without a case signal, but the way of doing that with my build method is pretty unconventional.

Tools




Vise: I make the heatsinks with an interference fit (AKA press-fit) for DTR's modules, which can be pressed in with a vice using moderate strength. An interference fit is best for thermal transfer, no thermal grease necessary. The type of vise I'm using here is a 4" drill press vise.

Trigger clamp (or any clamp really): Used for holding the contact plug in while the adhesive is drying. A good idea might be to use a larger clamp when gluing the heatsink to the body if it's not threaded.


Tutorial


It's easy!

This is optional, but I like to line the bottom of the vise with duct tape to prevent any scratches:


Start off by pressing the module into the heatsink:



Once that's done, strip the wire and make a "hook" shape as shown:


Hook the wire onto the bolt and tighten down the nut:



Put on a thin coat of adhesive on the contact plug, and clamp it in place to dry. Set time will depend on the adhesive you use


Your heatsink should look a little something like this:


Remember, if the heatsink isn't threaded, make sure to be aware of the importance for this part - Mix the adhesive for a good minute or two (if using a type of epoxy), spread evenly (light coat) and clamp together. Wipe off any excess while you can, because you won't be able to get it off once it's cured.




Ready for batteries!

-E.P.


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Old 07-11-2017, 11:25 PM #2
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Default Re: EP's Host Build Guide

Excellent thread EP !
Thank you for putting this together {pardon the pun}.

+rep when I can.

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Old 07-11-2017, 11:32 PM #3
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Default Re: EP's Host Build Guide

Oh, so you've gone to pressed hosts just like some of sinner's hosts. Yeah, that's how it's done, alright. Nice tutorial, EP.
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Old 07-11-2017, 11:52 PM #4
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Default Re: EP's Host Build Guide

Nice tutorial EP, makes it plan and very simple. You might want to mention/show the pinch method with the ground wire on the contact board for those people that don't have, didn't buy a module that is case grounded. Like me.
It's all pretty simple/basic though. Just thought I mentain it. It all makes your builds/hosts very easy and quick to work with. Nice
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Old 07-12-2017, 12:13 AM #5
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Default Re: EP's Host Build Guide

Thanks guys, glad you like the thread. Nice one Andrew, I even made that pun myself on the first sentence of this thread, and didn't even notice it!

Yea Paul, beats having to deal with thermal grease by a ton.

Quote:
Originally Posted by BobMc View Post
Nice tutorial EP, makes it plan and very simple. You might want to mention/show the pinch method with the ground wire on the contact board for those people that don't have, didn't buy a module that is case grounded. Like me.
It's all pretty simple/basic though. Just thought I mentain it. It all makes your builds/hosts very easy and quick to work with. Nice
You're right Bob, I forgot about that. I've since moved away from that method, and instead encouraged to solder to the case pin on the diode. But I guess in the end they're both equally as good. If you have some pics of any of your builds using the "pinch method", please, feel free to post them. Otherwise I'll try to see if I can get some photos myself.
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Old 07-12-2017, 12:26 AM #6
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Default Re: EP's Host Build Guide

Quote:
Originally Posted by ElectricPlasma View Post


You're right Bob, I forgot about that. I've since moved away from that method, and instead encouraged to solder to the case pin on the diode. But I guess in the end they're both equally as good. If you have some pics of any of your builds using the "pinch method", please, feel free to post them. Otherwise I'll try to see if I can get some photos myself.
No sorry photobucket has my photo's and they're holding them for ransom.

It pretty simple though, you just strip back the wire enough to twist around the part of the contact board that gets pushed into to heatsink. If you do it just right it make a tight fit so you don't have to use epoxy to hold the contact board in. (The wire takes up the slack and make a tight fit.) Also it's easier to undo if you ever want to change out the module. Done it on a few of your hosts, works quite well.

Ps, just don't let the two (bare part) of wires touch and you good to go.
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Old 07-12-2017, 12:59 AM #7
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Default Re: EP's Host Build Guide

Nice build tutorial EP!
+rep!
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Old 07-13-2017, 05:13 PM #8
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Default Re: EP's Host Build Guide

Great Job, EP!
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Old 07-13-2017, 05:53 PM #9
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Default Re: EP's Host Build Guide

Nice, I miss posts like this, glad a few members are taking the time to do this.
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Old 07-15-2017, 03:41 AM #10
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Default Re: EP's Host Build Guide

Wow! For some reason I had no earthly idea how exactly to make modules Case negative because most of DTR lasers are neutral so I didn't need to worry about this, but now that I would need to do this if I purchased one of these hosts I just realized how to do by reading your post, you just solder basically the black wire that you would normally solder to the brass ring of the pill to the little case pin instead right?
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Old 07-15-2017, 04:37 AM #11
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Default Re: EP's Host Build Guide

Actually, if the diode has a case pin and you want to make your diode case negative, you solder the case pin to the cathode pin and you're done. It's that simple.
However if you need a current path for the driver the negative lead needs to be connected to the case somehow. One way of doing this if the module makes a good connection to the case is to solder it to the case pin.
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445nm 2.2 watts Nichia MS Envy

445nm 2 watt SMP Copper Host
477nm 127 mW 501B
488nm Uniphase #2201-20SLAT argon laser head and power supply >40mW
520nm LaserLands pointer
532nm LSR532H-1W Laser, LSR-PS-N1 Driver, RS-75-5 P.S. 1300 mW
532nm 200mW Thermostatically Controlled Fan Cooled (Besram) >230mW
532nm 189mW pocket lab laser
532nm lasers X6 100mW-200mW
532nm lasers X4 75mW- 140mW
632.8nm P210 New Laser Tube 0.57mW Melles Griot 05-LMP-827-037 PS
632.8nm Spectra- Physics He- Ne #102-2 4mW heads X2 and #236 power supply
632.8nm PMS He-Ne # 201P/ LPS-115 2mW
632.8nm Siemens HeNe LGK7630S 7.6mW
635nm 1 watt Cyprus II
635nm 1 watt SMP Copper host
635nm 5mW pointer
635nm 100mW pointer
635nm Lifetime17 Mini-camo build 687mW
650nm 65mW pointer
650nm 380mW 501B
808nm 1+W infrared laser
infrared video camera for collimating IR lasers
Ocean Optics USB2000 Spectrometer
Scientech Vector S310 with AC2500 10 Watt LPM
LaserBee II 3.2 Watt LPM
Radiant X4 3.7 Watt LPM

Last edited by paul1598419; 07-15-2017 at 05:53 AM.
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Old 07-16-2017, 12:45 AM #12
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Default Re: EP's Host Build Guide

Quote:
Originally Posted by paul1598419 View Post
Actually, if the diode has a case pin and you want to make your diode case negative, you solder the case pin to the cathode pin and you're done. It's that simple.
However if you need a current path for the driver the negative lead needs to be connected to the case somehow. One way of doing this if the module makes a good connection to the case is to solder it to the case pin.
Ohhh, Okay that's good you clarified that for me because I would have totally screwed that up, lol
Thanks Paul
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405nm Sky-Lasers 89mw pen series
405nm 801mw C6 build 16X G2
445nm 1220mW Scifi 501b
445nm 598mw trustfire mini. thanks Raz.
445nm 1000mw Sky-Laser handheld (soon)
450nm 1690mW c6 pltb450b build
462nm 1590mw (avg) Jetlasers Equality
520nm 50mw Osram PL520 C6 Build (soon)
520nm 188mw Scifi lasers.
532nm 50mw(38mw) Lazerer
532nm 101mw Streamlight stylus Pro (thanks Pman)
532nm 92mw River Rock Pman build
638nm 531mw Oclaro C6
650nm 121mw Wicked laser P125
650nm 186mW Rayfoss 14500 host
650nm 230mw Pman build!! Might be my Favorite.

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