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Old 05-22-2012, 07:07 PM #1
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Default Rebuilding the dorcy jr. old style host FREAK build

Hey guys,

Last few days I have been doing some work on the old style Dorcy host which i now also sell! This is just a quick tutorial on how i rebuild the pill I even cried during this build because when i tested it for the first time the diode led'd and the driver shorted for some vague reason so i rebuilded it again

So what you need:

- Solder flux
- Solder
- Tailcap (used orange one here)
- A nail
- Silicone wire (flaminpyro)
- Thermal glue

Then you can begin

I started with pulling out the old driver from the pill because that was trashed I also found a old german coin which I thought could be handy :





I thought what could we do here... I put the tailcap in the pil and it fitted great so i glued that in there.

Next I grabbed a nail and cutted of the a long part and soldered a silicon wire on it. I used heatshrink for extra reinforcement and isolation.



Then I made a small hole in the tailcap and i got the wire through and this is what i ended up with:





Then I polished me old coin and drilled some holes in it. The hole in the middle was to screw it on my dremel so i could hold it against sandpaper to make it exactly the right size!





Then in the first hole I put a wire through and soldered it to the coin (ground) I had the idea to pressfit the coin in which then grounds with the host. I just heated the coin untill the solder melted.







Next I got my ben boosts from cilegray, so that was the driver of choice!







Then I glued the driver to the pill with thermal glue I got from Blord







Then I pressed the pill back in the host again:



soldered the last wires onto it an tested it on a testload:





Last I soldered the diode onto it! Don't forget to short the wires of the driver!



Thanks for looking

greetings,,

EDIT: Forgotten finished product







UPDATE:

In my never ending quest for improving things I rebuilt the dorcy again

I removed the benboost with another one set at 1A.

Also I got a brand new M-140 with a 405-G2:



Next to optimise heat transfer to the heatsink and host I cut the back of a Aixiz module in two pieces and screwed the back on the module again with Arctic silver:



This entire module is then arctic silver'd to the heatsink to improve duty cycles.

LPM on it's way


EDIT:

This diode seems to be very efficient this little one packes a punch now 1.8W!!!!

Here is the lpm video:



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Last edited by offroadfreak8582; 06-12-2012 at 12:46 PM. Reason: spelling
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Old 05-22-2012, 07:16 PM #2
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Default Re: Rebuilding the dorcy jr. old style host

Nice rebuild. A lot of pictures
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Old 05-22-2012, 07:18 PM #3
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Default Re: Rebuilding the dorcy jr. old style host

I thought it was looking kinda ghetto but the end product looks good to me!
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Old 05-22-2012, 07:59 PM #4
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Default Re: Rebuilding the dorcy jr. old style host

Looks good, very inginuitive(sp) =]

Where exactly do you sell the old dorcy hosts?
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Old 05-22-2012, 08:01 PM #5
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Default Re: Rebuilding the dorcy jr. old style host

Quote:
Originally Posted by bloompyle View Post
Looks good, very inginuitive(sp) =]

Where exactly do you sell the old dorcy hosts?
I said it in my ehgemus 445 sales thread and i only have this one so i you are interested pm me

Greetings,,
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Old 05-22-2012, 10:24 PM #6
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Default Re: Rebuilding the dorcy jr. old style host

Thanks for doing this. I enjoyed seeing a classic build appear again!
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Old 05-22-2012, 11:05 PM #7
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Default Re: Rebuilding the dorcy jr. old style host

Thanks for the nice comments

And because you all love moah pictures i added the end product with nice beam shots

greetings,,
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Old 05-23-2012, 08:04 PM #8
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Default Re: Rebuilding the dorcy jr. old style host

and awesome rebuilding you did there man
The new dorcy also looks the brightest of all
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Old 05-23-2012, 08:58 PM #9
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Default Re: Rebuilding the dorcy jr. old style host

I have three or four in my round TUIT box just waiting for the right doides to make a matched set. Love those old Jrs.. Harder to find nowadays. Mine are NFS btw.

+2 for the rebuild and great pics- this one needs to go into the Tut subforum.
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Old 05-24-2012, 10:32 PM #10
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Default Re: Rebuilding the dorcy jr. old style host

Quote:
Originally Posted by hakzaw1 View Post
I have three or four in my round TUIT box just waiting for the right doides to make a matched set. Love those old Jrs.. Harder to find nowadays. Mine are NFS btw.

+2 for the rebuild and great pics- this one needs to go into the Tut subforum.
Thanks nice comments make builds worth while yeah if daguin agrees it's fine with me to put it in the tutorials thread!

Greetings,,
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Old 05-27-2012, 10:03 AM #11
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Default Re: Rebuilding the dorcy jr. old style host

Very nice rebuilding process
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Old 05-27-2012, 11:56 AM #12
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Default Re: Rebuilding the dorcy jr. old style host

anyone know where you can get any of these hosts?
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Old 05-31-2012, 03:26 PM #13
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Default Re: Rebuilding the dorcy jr. old style host

Hey guys,

In my never ending quest for improving things I rebuilt the dorcy again

I removed the benboost with another one set at 1A.

Also I got a brand new M-140 with a 405-G2:



Next to optimise heat transfer to the heatsink and host I cut the back of a Aixiz module in two pieces and screwed the back on the module again with Arctic silver:



This entire module is then arctic silver'd to the heatsink to improve duty cycles.

LPM on it's way and OP updated

greetings,,
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Old 06-12-2012, 12:18 PM #14
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Default Re: Rebuilding the dorcy jr. old style host FREAK build

Oke guys got mixed feelings about today I first started the day with killing a brand new A-140 so i was really pissed off!

Then is installed the new M-140 in the dorcy with a new 405-G2 and a AW IMR 16340 and took a lpm reading....

OMG

This is the most efficient diode i ever owned With a normall glass lens it peaks at about 1400mW and with the 405-G2 1800mW

What driver current you ask? 1017mA

Here is the lpm video:

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Last edited by offroadfreak8582; 06-12-2012 at 12:18 PM.
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Old 06-12-2012, 12:42 PM #15
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Default Re: Rebuilding the dorcy jr. old style host FREAK build

this thread is all over the place still good photos and as always nice beamz
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Old 06-12-2012, 12:44 PM #16
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Default Re: Rebuilding the dorcy jr. old style host FREAK build

Quote:
Originally Posted by jander6442 View Post
this thread is all over the place still good photos and as always nice beamz
All over the place? You mean not very clear? that can be changed

greetings,,
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