This 'Pocket Pal' Tutorial is for the DX sku 46 host, or blue VicLight host. (shown)


For a nice pocket sized DIY laser, here is a tutorial for my 'Pocket Pal' *laser.

Note, this build can be fit for a Meredith module, or an AixiZ. And is excellent for a red, or a blu-ray! It is a very versatile build!

This looks like the same light (different color): DealExtreme: $2.95 Compact 9 LEDs Flashlight But it requires a slightly adjusted heatsink. I have heatsink dimensions for this DX host now! It is the exact same build as this tutorial.

The host I use, is made by VicLight. Model LF-D01 This is the host:
L.A. Lighter, Inc. (***New Address***)


Note: If you want a heatsink, just let me know if it is for the DX sku 46 host! And which Module you want it fit for. Meredith or AixiZ. The thick o-ring spacer (see picture in this tutorial), will be included. ($23 plus shipping)

You will need a 1.5mm Allen wrench for the heatsink set screw. (wrench not included)


Using 3 X AAA batteries. I like the Lithium primaries!


* First step is to take the light apart...

That 'trimmed' thin metal washer will go back in last, after the mod is done.
* Next, (read notes on picture)

Use your DMM to test continuity on the board for the driver connections to positive and negative.
* Now, take a very close look at this next picture...

The plastic piece that we cut the center out of and 'flipped' around, makes space for the FlexDrive.

* Set driver current. For the FlexDrive, you must use a load to set the current. (Six silicon diodes (1N4001) in series, work perfect for a blu-ray) Here's a good diagram from rog8811 on how to set up a 'dummy load' for a red diode/DDL driver (works the same for the FlexDrive), for a blu-ray, just use 6 instead of 4:
http://laserpointerforums.com/laser_pointer_forums_3/forum/showthread.php?t=26349#2
* Solder wires. Don't forget the heat shrink tubing.
* After placing the board/driver into position, use the thin metal washer that we 'trimmed'.
* It goes in last. This washer makes contact with some negative solder points on the board. As you tighten the case, it makes contact with the thin washer, 'pressing' the o-ring 'cushion' tight. Giving good ground, and stabilizing the heatsink.

The result, is a very solid, but pocket sized, awesome little laser!



To finish it off, you can make a nice 'dust cap' from these silicone tailcaps: DealExtreme: $2.10 Silicone Tailcaps for Flashlights (14mm in Assorted Colors / 12-Pack)
Which come in different colors as well.

You just turn it 'inside out', and cut the little 'nub' off. (Thank Senkat for that one!)...
Jay

P.S. The battery holder (whether it be black or clear), has these small 'tabs' at a couple of points where the POSITIVE end of the batteries need to make contact with the flat metal contact points.

Use a knife and 'snap' or cut the tabs to make sure your batteries make good contact. The thickness of the tabs can cause a weak connection, or no connection at all...

P.S.S. If you do not want to use the Lithium primaries, but like rechargeable batteries better, the Sanyo Eneloop batteries are the best...


Update: I examined the DX sku 46 host and it is basically identical... it will be the same exact tutorial. There are some very slight differences...



The very front, where the heatsink protrudes through, is a little smaller in diameter. Also, the total distance in the head, is a little longer.

So, the heatsink will be adjusted to fit, and this host can be used to follow this tutorial exactly! ($23 plus shipping)

Note: The heatsink will be .050 in. longer at the back (inside the host). This is to compensate for the slightly longer distance inside the head space of this host...





Click here to see my list of projects and tutorials!

Very cool *

I appreciate how you not only sell them, but also have full disclosure on how you make them. It just says a lot about one's character when they aren't afraid of being 'ripped off' or losing money by divulging their techniques. Good work as always! *8-)

EDIT: Nice guitars... I have a jackson soloist

Nice...you must play lead guitar too then!

Hey thanks for your good words there!
Jay

everybody loves guiars, i got an ibanez, ohh right.
and jayrob, i think i have seen you around at iceinspace.
edit: i am hoping to try this, will an aixis (if thats how its spelt) fir into the flashlight with the batteries.
so, will the 3 AAA's still be the power suply, i guess you use them but is your module as long as the one i wish to use.
good stufff by the way, awesome purple exterior with a matching beam.
you happen to know where i can get low powered (10-50mw) diodes with different wavelengths.

Iceinspace? Doesn't ring a bell...

About the build, yes, using the 3 X AAA supply.
The room inside is very limited. Only enough room for the front of the AixiZ module, not the back barrel. It will fit a Meredith module too!

As far as the low powered diodes, I'm sure someone here can chime in on a source. I have never looked into low powered diodes. But I know that you can buy an AixiZ module (or, same size) from DX that has a low powered red diode in there:
http://www.dealextreme.com/details.dx/sku.5914
Jay

That's the host I'm going to use for my blu-ray.

Great tutorial, now I won't even need my brain!

[smiley=tekst-toppie.gif]

Very nice, though the flashlight I have that's nearly exactly like that has a crappy clicky switch :|

Thanks for the compliment! I hope this tutorial serves you well...



This little host, by the way, has a very nice clicky switch![smiley=thumbsup.gif]

The only thing you will find, is that the threads are 'dry'. Use a little 'dielectric tune up grease'. It's a good habit to use dielectric tune up grease for this, because usually, the negative current travels through the threads...
Jay

Thanks for the compliment! I hope this tutorial serves you well...



This little host, by the way, has a very nice clicky switch![smiley=thumbsup.gif]

The only thing you will find, is that the threads are 'dry'. Use a little 'dielectric tune up grease'. It's a good habit to use dielectric tune up grease for this, because usually, the negative current travels through the threads...
Jay
[/quote]

Great instructable Jay maybe you mean conducting grease though dielectric grease does not conduct electricity.

Thanks!

Here's the stuff that I have always used for electrical connections:
http://www.royalenfieldusa.com/perma...se-p-6676.html
In the description, it says that it does conduct electricity...
Jay

Thanks!

Here's the stuff that I have always used for electrical connections:
http://www.royalenfieldusa.com/perma...se-p-6676.html
In the description, it says that it does conduct electricity...
Jay
[/quote]

Guess I need to find a new dictionary

Nice guide!
They also sell a 2-pack, in case you want two..
http://www.dealextreme.com/details.dx/sku.1099
It's not much cheaper, but will save you some pocket change.

I like the unit and the blue anodizing is very cool!

Thanks guys! It really is a nice mod. That's why I wanted to show it. Perfect battery/driver set up too!
Jay

how long would normal duracell aaa's last. and how long do your lithiums last. theyre expensive :/

You know, I don't know the answer to that yet! I only turn mine on at night...maybe 5 or 10 minutes... a couple times a week. So, it doesn't get a lot of use. But I have not had to change the batteries yet. I guess it's been 3 or 4 weeks for this one.

But knowing that the current is only at 100mA's (for mine), and that the capacity for 3 X AAA, is more that the red build, which is 2 X CR123 (I believe 3 AAA is more capacity).

But in that comparison, the red burner builds that I am talking about, are running at 420mA's or more! And they last at least an hour. So, I think an educated guess, would be at least 4 hrs. runtime with the Pocket Pal @ 100mA's.

I have not even tried Duracell. I only use Energizer e2 Lithium.

Hopefully someone else can chime in here...
Jay

Hey Jayrob! Cool blue ray laser, do you think http://cgi.ebay.com/NEW-MINI-3-AAA-9...QQcmdZViewItem would work?

I can't really say. At the first post, I mentioned that there are some 'look alike' flashlights. One member told me that the look alike one from DX worked with my heatsink, but only after he did some Dremel work at the top lip of the host.

I have a link to the exact light that I use. Made by VicLight...
Jay

Very nice guide. I think I'll just make myself on of these! Do you have the correct measurements for your heatsinks to work with this flashlight? http://www.dealextreme.com/details.dx/sku.46
I want to make one so bad

EDIT: Where can I buy 6 silicone diodes? :-?

If you send me the light, I can adjust the heatsink. That way I can have the correct heatsink dimensions for that light from DX.

The silicon diodes are here:
http://www.digikey.com/scripts/DkSea...=1N4001DICT-ND
Jay

If you send me the light, I can adjust the heatsink. That way I can have the correct heatsink dimensions for that light from DX.

The silicon diodes are here:
http://www.digikey.com/scripts/DkSea...=1N4001DICT-ND
Jay
[/quote]
Thanks for the link. Could you do me a favor? If you're not busy would you buy that torch from DX for me and sell me some silicone diodes if you have any spares along with a heatsink for the torch? Just trying to save some shipping costs If you think I'm trying to trick you or anything, I could pay you for the torch first.

I will order one right now... It will take about 2 or 3 weeks to get it though.

I will contact you when I get it. At that piont, if you are still interested, I will fit a heatsink for it...
Jay

Ok, thank you very much. I'll order a driver from Dr Lava and a PHR-803T sled from Daedal soon. BTW Do you have any silicone diodes you can sell to me? If not I'll buy some from the link you gave me
Thanks again!

I don't have extra ones. They are cheap though. You'll just have to pay the $5 dollar handling fee from Digikey...
Jay

Love the laser wish I could afford it!
Also thanks for the guide on making it!
it'll help me when I end up making mine!