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-   -   !!!1W of purple!!! Lighthound 2xAA (14500) 405nm 12X Handheld Minitorch (https://laserpointerforums.com/f52/1w-purple-lighthound-2xaa-14500-405nm-12x-handheld-minitorch-75112.html)

danefex 06-09-2012 05:25 AM

!!!1W of purple!!! Lighthound 2xAA (14500) 405nm 12X Handheld Minitorch
 
Greetings Folks!

A few days ago I was happy to experience breaking the 2W barrier with this laser I'd just built & thought to aim for something groundbreaking (to me anyways) again! While I wasn't sure that I'd come close to where I was hoping to land, I am happy to share the results of my latest build with you!! A 1 Watt 12X 405nm purple scorcher that resembles a mini handheld lightsaber. Have a look at how it all came together... :D

The host - Lighthound 2xAA Tactical Flashlight
https://encrypted-tbn0.google.com/im...Pnop11ap4QyY_Q

Parts - Lighthound host, 12X BDR-S06J, ~680mA pipsqk, jayrob custom heatsink,
battery contact, 2x14500 Batteries (not pictured)

http://i101.photobucket.com/albums/m...g?t=1339215165

I've already soldered the leads on the diode because I was going to use this 12X in
a different host for another laser, but just before finishing that build I discovered
the host didn't conduct current. Build fail, I know :( The driver here I'm going to
re-use is from an older project that I've since dissembled. There's some used parts
going into this new laser ;)

http://i101.photobucket.com/albums/m...g?t=1339215166

First thing I need to do is get these wires out of this driver

http://i101.photobucket.com/albums/m...g?t=1339215166

Soldered out
http://i101.photobucket.com/albums/m...g?t=1339215166

If you ever need to do this you'll find that solder fills the holes in the driver after
you've gotten the wire out. Reopening those holes can be a pain but I've found a
pretty easy method of clearing the solder up. Take a safety pin & press it down onto
the blocked hole

http://i101.photobucket.com/albums/m...g?t=1339215166

Press your soldering iron on the opposite side of the driver & push the pin against
the tip of the iron through the driver. You should be able to do this in 1/2 a second

http://i101.photobucket.com/albums/m...g?t=1339215166

Once this pin is through, rotate it as you remove it from the hole gently enough not
to damage the driver but also to remove any broken solder that has reattached
itself to the pin

http://i101.photobucket.com/albums/m...g?t=1339215166

Repeat this process with all 4 holes & you'll be ready for some new leads

http://i101.photobucket.com/albums/m...g?t=1339215166

Now to putting the inside together

http://i101.photobucket.com/albums/m...g?t=1339215166

405 diode mounted into module, module mounted into heatsink
http://i101.photobucket.com/albums/m...g?t=1339215166

Running the diode leads through the pill
http://i101.photobucket.com/albums/m...g?t=1339215166

Soldered the leads to the bottom of the driver

http://i101.photobucket.com/albums/m...g?t=1339215166

Cheapy chinese driver I'm going to use for a battery contact after I remove all of
its components

http://i101.photobucket.com/albums/m...g?t=1339215166

Components removed
http://i101.photobucket.com/albums/m...g?t=1339215166

Positive lead soldered

http://i101.photobucket.com/albums/m...g?t=1339215166

Negative lead soldered
http://i101.photobucket.com/albums/m...g?t=1339215166

Battery leads soldered to driver
http://i101.photobucket.com/albums/m...g?t=1339215166

There's already heatsinks on both sides of this driver & it looks like there's enough
gap between the soldering points & its mounting surface (side view)

http://i101.photobucket.com/albums/m...g?t=1339215166

Front view
http://i101.photobucket.com/albums/m...g?t=1339215166

I'm going to add an additional layer just to play it safe on how it's going to be
mounted in the pill

http://i101.photobucket.com/albums/m...g?t=1339215166

Mixing up some thermal adhesive compound will do the trick

http://i101.photobucket.com/albums/m...g?t=1339215166

A nice thick layer of compound is used for maximum bonding & heat transfer

http://i101.photobucket.com/albums/m...g?t=1339215166

Stuffed it in the pill, 1/2 hr to completely dry
http://i101.photobucket.com/albums/m...g?t=1339215166

Closed up the pill, now to put the host back together
http://i101.photobucket.com/albums/m...g?t=1339215184

http://i101.photobucket.com/albums/m...g?t=1339215185

2 14500s charged & ready

http://i101.photobucket.com/albums/m...g?t=1339215185

It's together, now I just need to add the 405-G-1 lens

http://i101.photobucket.com/albums/m...g?t=1339215185

...and it's done!!
http://i101.photobucket.com/albums/m...g?t=1339215185

I set the laser down & turned it on to get a completed build picture, it immediately
started burning the rubber grips on one of my wrenches!!

http://i101.photobucket.com/albums/m...g?t=1339215185

Now for an LPM reading......


Well I wasn't sure if it'd happen or not, but I'm happy to announce that I've broken the 1W of 405 barrier!!! Thanks for checking this project out, let me know what you think
:D :beer:

T_Warne 06-09-2012 05:53 AM

Re: !!!1W of purple!!! Lighthound 2xAA (14500) 405nm 12X Handheld Minitorch
 
Another great tutorial. Congrats on the 1W milestone!!! I really like that host, but GAWD!, it's pricy.

grainde 06-09-2012 08:34 AM

Re: !!!1W of purple!!! Lighthound 2xAA (14500) 405nm 12X Handheld Minitorch
 
Really impressive! :gj: Where was the SO6J from eg DTR, sled or extracted from working burner? :thanks:

Machinist Joe 06-09-2012 08:41 AM

Re: !!!1W of purple!!! Lighthound 2xAA (14500) 405nm 12X Handheld Minitorch
 
Wow. Clean build man. My next project is 1W of 405. Going to buy quite a few 405 diodes and bin them to find the more efficient ones.

Blord 06-09-2012 09:20 AM

Re: !!!1W of purple!!! Lighthound 2xAA (14500) 405nm 12X Handheld Minitorch
 
Comprehensive photo shoot. An other good build !
Did you solder the battery contact to the aluminium host ? That was pretty hard.
It was easier with a brass ring in between.

danefex 06-09-2012 02:02 PM

Re: !!!1W of purple!!! Lighthound 2xAA (14500) 405nm 12X Handheld Minitorch
 
Quote:

Originally Posted by T_Warne (Post 1084545)
Another great tutorial. Congrats on the 1W milestone!!! I really like that host, but GAWD!, it's pricy.

You think so? It's certainly not cheap but I didn't think $29 was too bad.... I ordered a couple of them back & the price seemed ok, but this was also after I'd ordered a few of these expensive hosts ;)

Quote:

Originally Posted by grainde (Post 1084561)
Really impressive! :gj: Where was the SO6J from eg DTR, sled or extracted from working burner? :thanks:

Thanks! The diode was 1 of the 2 sleds I ordered from Scopeguy's 12X group buy $45. One of my sleds had the ~200mW low powered 'fake' diode that I'd love to get replaced & the other had this massive little monster I'm using in the lighthound :eg:

Quote:

Originally Posted by Machinist Joe (Post 1084562)
Wow. Clean build man. My next project is 1W of 405. Going to buy quite a few 405 diodes and bin them to find the more efficient ones.

Awesome, good luck Joe. It's not easy finding one that can do 1W but they are definitely out there :beer:

Quote:

Originally Posted by Blord (Post 1084566)
Comprehensive photo shoot. An other good build !
Did you solder the battery contact to the aluminium host ? That was pretty hard.
It was easier with a brass ring in between.

Thanks Blord. No the contact isn't soldered to the pill, I find it nearly impossible getting solder to stick to aluminum. I generally stick some solder along the copper sides of the battery contact to create enough tension between the board & the pill to keep it in place. Since the solder sticks much better to the copper on the contact board, I'm always able to get enough in there for a secure, conductive 'press' that stays snugly in place :D

532 with Envy 06-09-2012 02:13 PM

Re: !!!1W of purple!!! Lighthound 2xAA (14500) 405nm 12X Handheld Minitorch
 
Love the build tutorial....Great job!

Congratulations on the 1W milestone as well. That's a lot of punch for a 405nm:lasergun:

Garoq 06-09-2012 02:32 PM

Re: !!!1W of purple!!! Lighthound 2xAA (14500) 405nm 12X Handheld Minitorch
 
Excellent work Dan! :bowdown: I'm going to have to try something like this one of these days.

danefex 06-09-2012 07:29 PM

Re: !!!1W of purple!!! Lighthound 2xAA (14500) 405nm 12X Handheld Minitorch
 
Quote:

Originally Posted by 532 with Envy (Post 1084600)
Love the build tutorial....Great job!

Congratulations on the 1W milestone as well. That's a lot of punch for a 405nm:lasergun:

Thanks 532!! 1 watt of violet is a whole new shade of purple & having that power in a handheld feels awesome :beer:

Quote:

Originally Posted by Garoq (Post 1084606)
Excellent work Dan! :bowdown: I'm going to have to try something like this one of these days.

Thank you as well Gary! I wish you luck on doing something very similar like this & breaking 1W of 405 to experience it for yourself :beer:

Garoq 06-09-2012 09:02 PM

Re: !!!1W of purple!!! Lighthound 2xAA (14500) 405nm 12X Handheld Minitorch
 
Thanks Dan! Although, it appears that I just blew 2 12X diodes during testing at 445mA. :banghead:

Elektrotechniker 06-09-2012 09:08 PM

Re: !!!1W of purple!!! Lighthound 2xAA (14500) 405nm 12X Handheld Minitorch
 
is the beam visible in the night? :D

danefex 06-09-2012 09:48 PM

Re: !!!1W of purple!!! Lighthound 2xAA (14500) 405nm 12X Handheld Minitorch
 
Quote:

Originally Posted by Garoq (Post 1084755)
Thanks Dan! Although, it appears that I just blew 2 12X diodes during testing at 445mA. :banghead:

:( I am sorry to hear that Gary, I completely understand suffering the loss from losing valuable diodes

Quote:

Originally Posted by Silvershot (Post 1084756)
is the beam visible in the night? :D

:crackup: I think the important question to ask here is.......... can it pop balloons? :beer:

scopeguy20 06-09-2012 11:34 PM

Re: !!!1W of purple!!! Lighthound 2xAA (14500) 405nm 12X Handheld Minitorch
 
Peoples eyes will "see" violet differently, to my eye a 30 mW 405 had no violet color in the night sky seen beam, was over the top excited at the first 150 mW and even more the first 500mW ones I got! My best was a 850mW 405nm laser, (currently being repaired). Yes the beam is seen and has purple color at >200 mW for all I have asked to look and relate...

btw, you should see a scorpion with a 850 mW 405 trained on it from a distance... looked like you could read by the green light! :D

-GH

danefex 06-10-2012 04:17 AM

Re: !!!1W of purple!!! Lighthound 2xAA (14500) 405nm 12X Handheld Minitorch
 
Nice! I'll definitely bring this out to the desert with me the next time I travel. Scorpion hunting sounds awesome & I imagine they'd glow bright as hell being hit with that much 405 hehe :beer:

lowell389 06-10-2012 05:27 AM

Re: !!!1W of purple!!! Lighthound 2xAA (14500) 405nm 12X Handheld Minitorch
 
That is one slick looking, powerful 405
Nice work!

lasersbee 06-10-2012 11:29 AM

Re: !!!1W of purple!!! Lighthound 2xAA (14500) 405nm 12X Handheld Minitorch
 
Nice work Dan...
I really like the Host and your build skills are getting
even better...:gj:


Jerry

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