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 :beer: 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 :wtf:

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 :angel: 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 :yh:







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 :beer:

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 :beer:


EDIT:

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

Here is the lpm video:

Re: Rebuilding the dorcy jr. old style host

Nice rebuild. A lot of pictures

Re: Rebuilding the dorcy jr. old style host

I thought it was looking kinda ghetto but the end product looks good to me!

Re: Rebuilding the dorcy jr. old style host

Looks good, very inginuitive(sp) =]

Where exactly do you sell the old dorcy hosts?

Re: Rebuilding the dorcy jr. old style host

bloompyle said:

Looks good, very inginuitive(sp) =]

Where exactly do you sell the old dorcy hosts?

Click to expand...

I said it in my ehgemus 445 sales thread and i only have this one so i you are interested pm me

Greetings,,

Re: Rebuilding the dorcy jr. old style host

Thanks for doing this. I enjoyed seeing a classic build appear again!

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 :beer:

greetings,,

Re: Rebuilding the dorcy jr. old style host

:kewlpics: and awesome rebuilding you did there man :beer:
The new dorcy also looks the brightest of all :gj:

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.

Re: Rebuilding the dorcy jr. old style host

hakzaw1 said:

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.

Click to expand...

Thanks nice comments make builds worth while :beer: yeah if daguin agrees it's fine with me to put it in the tutorials thread!

Greetings,,

Re: Rebuilding the dorcy jr. old style host

Very nice rebuilding process

Re: Rebuilding the dorcy jr. old style host

anyone know where you can get any of these hosts?

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 :beer:

greetings,,

Oke guys got mixed feelings about today :shhh: 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 :drool: :drool:

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

What driver current you ask? 1017mA

Here is the lpm video:

this thread is all over the place:can: still good photos and as always nice beamz

jander6442 said:

this thread is all over the place:can: still good photos and as always nice beamz

Click to expand...

All over the place? You mean not very clear? that can be changed :shhh:

greetings,,