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Old 10-15-2010, 03:48 AM #1
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Default My 1st DIY 1.6W 445 handheld (Image heavy)

I got a lathe 4 days ago and have been learning how to use it.
I figured "what better way then to make a heatsink?" ^_^
Took a few attempts to get something I liked but this is what I came up with:
The first attempt was supposed to go under the glass of the flashlight host and fit exactly like a p60 drop in (waterproof FTW!!!) but The wire I have ordered from flaminpyro hasn't showed yet and the wire I do have was going to break the leads of the diode off... Need more room
Back to the drawing board.
This was the second attempt, remove the glass stick the heatsink out in front

I screwed up and made the relief for the board a little too big plus I got some chatter in a couple of places and made the part sticking out the front a little too narrow.
My third attempt I decided not to bother with the "negative terminal spring" and just made it to fit perfectly just as the threads bottom out. I also made the front part a bit longer because the 2nd one looked a bit stubby

The driver I used is easily obtained, producing 1.495mA steady (tested on a dummy load for 2 minutes), and very inexpensive (~$3) but I don't condone a step 1. step 2. step 3. approach to building a potentially dangerous laser. If a couple of the veterans think its a good idea, I'll edit the info in later but it is just a little too easy to do and even someone with no idea of the capacity could build this laser.
I'm planning a build with a bigger (read "wider") heatsink in another ultrafire host (top in the next pic) and keep that one under the glass. Are the back reflections hard on the diode at 1.6W?

From the top, this is an
ultrafire SSC P7-D emitter host,
Stainless steel Cree R2,
The 445 build with the 3rd attempt heatsink completed and ready to lase,
an 18650 battery for size reference ^_^
Of course there has to be at least one beamshot with such a pretty color

Hope you like my 1st build.


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2 - 5mW pointer

1 - "5mW" pen *overspec*
2 - 200mW "DX" pens
5 - 1W 808nm labbies (soon to have custom hosts)
3 - 1.6W 445 handheld in a professional home DIY host - 2 Sold
3 - "5mW" Ebay pens - 1 >30mW
1 - ~600mW 405 in a handmade heatsink + SS Cree host

Last edited by AUTO XX; 11-02-2010 at 09:57 AM.
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Old 10-15-2010, 03:55 AM #2
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Default Re: My 1st DIY 1.6W 445 handheld (Image heavy)

Nice Build!
Do you have an LPM?
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Old 10-15-2010, 04:14 AM #3
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Default Re: My 1st DIY 1.6W 445 handheld (Image heavy)

Thanks 00Giorge,
no LPM sorry, I just went by the current + lens type others had used and gave a guess
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2 - 5mW pointer

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2 - 200mW "DX" pens
5 - 1W 808nm labbies (soon to have custom hosts)
3 - 1.6W 445 handheld in a professional home DIY host - 2 Sold
3 - "5mW" Ebay pens - 1 >30mW
1 - ~600mW 405 in a handmade heatsink + SS Cree host
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Old 10-15-2010, 04:47 AM #4
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Default Re: My 1st DIY 1.6W 445 handheld (Image heavy)

Lookin good AUTO XX!

Cant wait till I can have a lath, cant at my current house
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Old 10-15-2010, 06:41 AM #5
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Default Re: My 1st DIY 1.6W 445 handheld (Image heavy)

this one is a smithy 1200 I think, I got it used for $350 canadian and spent about $400 on tooling.
The milling machine attached to it hasn't had any use yet but I should be able to figure that out pretty easily
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2 - 5mW pointer

1 - "5mW" pen *overspec*
2 - 200mW "DX" pens
5 - 1W 808nm labbies (soon to have custom hosts)
3 - 1.6W 445 handheld in a professional home DIY host - 2 Sold
3 - "5mW" Ebay pens - 1 >30mW
1 - ~600mW 405 in a handmade heatsink + SS Cree host
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Old 10-15-2010, 04:37 PM #6
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Default Re: My 1st DIY 1.6W 445 handheld (Image heavy)

Hey AUTO, about how large is your lath all together? Just wondering, looks like you got a pretty nice deal on yours.
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Old 11-02-2010, 09:56 AM #7
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Default Re: My 1st DIY 1.6W 445 handheld (Image heavy)

sorry for the LATE reply man, the lathe is a "smithy 1200" they seem like a decent deal new as well. Shipping would be a bugger though
I think its a 9" swing and a 3' bed. The main problem is that the milling machine is a set distance from the chuck and without removing the chuck, I only have 2" of travel on the x axis... I think I'm going to get a better milling vice though, its only about $100
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2 - 5mW pointer

1 - "5mW" pen *overspec*
2 - 200mW "DX" pens
5 - 1W 808nm labbies (soon to have custom hosts)
3 - 1.6W 445 handheld in a professional home DIY host - 2 Sold
3 - "5mW" Ebay pens - 1 >30mW
1 - ~600mW 405 in a handmade heatsink + SS Cree host
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Old 11-02-2010, 05:36 PM #8
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Default Re: My 1st DIY 1.6W 445 handheld (Image heavy)

Nice work Auto.

So do we have another LPF member that will be able to provide us heatsinks?
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Old 11-03-2010, 08:03 AM #9
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Default Re: My 1st DIY 1.6W 445 handheld (Image heavy)

I can but it seems like the headaches of shipping aren't worth it.
I'm a carpenter by trade so most of this stuff is 2nd nature but I tend to make things a little too close. I had to buy a cylinder hone today because in a steam engine I am working on the piston was .001mm under the cylinder size and I guess that was a little too close.
The heatsink I made yesterday for the little stainless aurora 18650 hosts had the same problem. You have to KNOW it will go in and even then, the machining burrs on the host's threads scraped up the sides of my pretty new heatsink lol
I could make heatsinks for you but it wouldn't be for any more money than the aluminum bar stock (and shipping) is worth.
I'm not in it for the money, it's just the experience that I'm interested in.
I have even been *****ter diving (with permission) in my buddies scrap metal bin (he owns a couple of welding/oilfield supply shops)

You would need to send the host to me, a note saying what you want done with the host and a couple of bucks for raw material ^_^
The other option is just dimensions. I can figure pretty much any crude drawing out :P
*I haven't bought an 8mm X 0.5 thread tap for the lenses if you wanted a direct pressfit heatsink.
It's $37 and I don't think it would pay for itself.
What I have done is machined down an aixiz module and it will pressfit into the heatsink without the chrome in the way.
I'll assemble the next laser and post some pics as soon as I get my flexies
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2 - 5mW pointer

1 - "5mW" pen *overspec*
2 - 200mW "DX" pens
5 - 1W 808nm labbies (soon to have custom hosts)
3 - 1.6W 445 handheld in a professional home DIY host - 2 Sold
3 - "5mW" Ebay pens - 1 >30mW
1 - ~600mW 405 in a handmade heatsink + SS Cree host
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Old 11-03-2010, 08:39 AM #10
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Default Re: My 1st DIY 1.6W 445 handheld (Image heavy)

Very nice build man,
You have a huge heatsink that can take more then 1.6w (you need heatsink for the driver for it.)
I loved the huge heatsink
I have the same WF-501B host I want to use for a high power laser and I'm intersted in a good HS.
Can you make me one the same as you have with your third attempt.
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Old 11-03-2010, 08:42 PM #11
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Default Re: My 1st DIY 1.6W 445 handheld (Image heavy)

I'd also be interested if you would like to make some more practice runs for experience like you were saying.
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Old 11-04-2010, 03:24 AM #12
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Default Re: My 1st DIY 1.6W 445 handheld (Image heavy)

Sure, I don't know what the shipping is worth getting it back to you but I'll only charge that plus a few bucks for the aluminum. I need the sizes though if it under 1" (example. "aurora cree R2") it will be cheaper, if it is over 1 1/4" it will be more expensive. I also might have to get some material shipped so it might take a bit longer but I can knock a heatsink of any dimensions out in about an hour tops.
I went out yesterday and bought a whole bunch of milling machine tooling too, I should be able to figure out the more intricate stuff but have no experience with it thus far so it might not be as professional
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2 - 5mW pointer

1 - "5mW" pen *overspec*
2 - 200mW "DX" pens
5 - 1W 808nm labbies (soon to have custom hosts)
3 - 1.6W 445 handheld in a professional home DIY host - 2 Sold
3 - "5mW" Ebay pens - 1 >30mW
1 - ~600mW 405 in a handmade heatsink + SS Cree host
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