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Old 06-08-2012, 07:30 PM #1
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Default 3W peak, 2.9W stable Juggernaut 445 TEC Maglite build log

Got my OPHIR head setup today
3W peak
and very stable at 2.9W
even did a 5 min run





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Today I am starting my "Juggernaut" Maglite build
I will be shooting for 3W,
but anything over 2.5W and I'll be happy




The 2 part heasink was custom made by Eudaimonium

Focus adapter will be made by Flamingpyro once he gets some larger alu stock

And I have a Custom Thermoelectic peltier to cool the diode,
The TEC will run off of 2 Lithium cells at 2.5 Amps
and has a qmax of 13.1 Watts

Total heat going into the maglite will be about 30 Watts
so the maglite will get hot, but the diode will stay cold

I'll have to do some testing to see if I need to under power the TEC some
(to prevent condensation)

Pics of what I have so far:





That last pic is what the focus adapter should look like


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Last edited by justinjja; 07-09-2012 at 08:41 PM.
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Old 06-08-2012, 07:35 PM #2
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Default Re: Juggernaut 445 Maglite build log

Interesting build. I am looking for the performance of the cold diode.
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Old 06-08-2012, 07:44 PM #3
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Default Re: Juggernaut 445 Maglite build log

Quote:
Originally Posted by justinjja View Post
And I have a Custom Thermoelectic peltier to cool the diode,
The TEC will run off of 2 Lithium cells at 2.5 Amps
and has a qmax of 13.1 Watts

Total heat going into the maglite will be about 30 Watts
so the maglite will get hot, but the diode will stay cold

I'll have to do some testing to see if I need to under power the TEC some
(to prevent condensation)
The results will be fascinating to see. I have seen significant jumps in power when a diode is cold.

Then of course there is the awesome benefit of a truly continuous duty cycle laser!

Since this is very experimental, if you can build in a way to power it without batteries at all... you'll have a labbie on your hands
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Old 06-08-2012, 07:45 PM #4
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Default Re: Juggernaut 445 Maglite build log

The TEC might now perform how you intend it to, I was told JETLASERs had to put fan and TEC cooling on back burner for the new Pro PL-D. The TEC has its own heat issues and without a fan they do not help all that much.
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Old 06-08-2012, 07:48 PM #5
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Default Re: Juggernaut 445 Maglite build log

Did you isolate the sink from the host ? If they are connected somehow the hot host will transfer the heat to to sink.
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Old 06-08-2012, 07:56 PM #6
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Default Re: Juggernaut 445 Maglite build log

Good luck on searching for a 3W diode
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Old 06-08-2012, 07:58 PM #7
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Default Re: Juggernaut 445 Maglite build log

Quote:
Originally Posted by eytyxhs View Post
Good luck on searching for a 3W diode
It might not even be a good idea to push those 9mm diodes that hard. There hasn't been much testing with them, they might degrade at higher currents.
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Old 06-08-2012, 07:58 PM #8
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Default Re: Juggernaut 445 Maglite build log

Quote:
Originally Posted by eytyxhs View Post
Good luck on searching for a 3W diode
Both DTR, and Lazeerer hit 3W with a tec, using the new 9mm diodes.
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Old 06-08-2012, 08:03 PM #9
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Default Re: Juggernaut 445 Maglite build log

He needs to buy a lot diodes to find something to hit at 3W.

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Old 06-08-2012, 08:25 PM #10
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Default Re: Juggernaut 445 Maglite build log

Quote:
Originally Posted by Blord View Post
Did you isolate the sink from the host ? If they are connected somehow the hot host will transfer the heat to to sink.
For the most part yes,
There is a slight thermal short going from the lens and focus adapter, but I doubt it will have much of an effect

Quote:
Originally Posted by InfinitusEquitas View Post
Both DTR, and Lazeerer hit 3W with a tec, using the new 9mm diodes.
Cool, I didn't realize Lazeerer had a 3W'er too, looks like this might be possible
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Old 06-08-2012, 08:32 PM #11
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Default Re: Juggernaut 445 Maglite build log

Hello roomie!

I'll be watching over him, making sure he actually hits my (errr his) 3W goal!
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Old 06-09-2012, 02:34 AM #12
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Default Re: Juggernaut 445 Maglite build log

I'm subscribing to this thread... Checking back often hope it works out.
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Old 06-09-2012, 03:50 AM #13
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Default Re: Juggernaut 445 Maglite build log

Quote:
Originally Posted by eytyxhs View Post
He needs to buy a lot diodes to find something to hit at 3W.
Quote:
Originally Posted by justinjja View Post
Cool, I didn't realize Lazeerer had a 3W'er too, looks like this might be possible
That's true. Also AFAIK the diodes were overdriven... meaning both DTR and Lazeerer were very well aware they could kill them. There is zero guarantee of longevity.

Honestly I think 2W+ and unlimited duty cycle is a very worthy goal by itself.
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Old 06-09-2012, 04:57 AM #14
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Default Re: Juggernaut 445 Maglite build log

Cool idea...

I'm wondering if you might possibly make room in there for a small fan?? (maybe drill holes out the front for intake, and holes out the sides on the back side for exhaust)

I only mention this because there has to be cooling of the 'heat' side of the TEC in order for it to work properly.

I did a couple of TEC builds in a box host a few years back: (12X upgraded)
Tutorial: Blu-Ray With TEC! - Step by Step

I still have both builds. They work perfectly, and the diode heatsink stays at room temperature...

I have had plans on doing a similar thing in a Mag host. I have the TEC, fan, heatsinks for TEC built. Just have not gotten around to putting it to use yet...

Edit: You have inspired me to finish my 445 Mag Mod with TEC...
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Old 06-09-2012, 09:52 AM #15
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Default Re: Juggernaut 445 Maglite build log

Ahh so THAT's how you're going to use that heatsink

Well, as long as the bigger part which is supposed to cool the TEC is thermally secured to the host, it shouldn't be all that too much to handle, you should regulate the TECs current to find out which level works best for you, in order not to over heat anything but still have it working effectively.

Also be very careful where your drivers are. You don't want them getting on the TEC's bad side
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Old 06-10-2012, 07:56 AM #16
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Default Re: Juggernaut 445 Maglite build log

update:

LPM'ed it with my Radiant Alpha,
No idea if the alpha is still accurate at this level,
but it was reading 2.6 Watts

I do have a Scientech head in the mail.

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