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2W 445 DTR Frankenstein Ultrafire RL-2088 Handheld Host

DTR

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I Am Proud to Introduce The

2W DTR Frankenstein










So I decided to make an awesome massive laser out of this unit.:eg:

I contacted Jayrob and he said he would make a heatsink for me and I sent it off to him.

He kept me up to date as he was working on it.


Here's how the modifications were done. Excellent work by the way. Jay is certainly a master at his craft.

He contacted me all worried that he would need to damage the reflector to get it out because it was glued heavily into the head. And he wanted to give me a chance to change my mind because there would be no going back. I told him he could bash it with a hammer if it made it look good.:crackup:






Next step was to remove the old driver from the head.









Then he drilled out the pill and made these nice little indentures so I could use to unscrew it. I kind of feel bad I did not even use it in the final build.








Again I feel bad because he modded the battery holder for 3X18650 in parallel that would give some amazing runtimes. And I ended up going with them in series.






He machined the head out and made this beautiful heatsking that is so massive that if you don't see it in person you don't fully comprehend how much mass it has. It might as well be a labby heatsink without the fins. It is fit for a 1/2in copper module.(I love overkill:eg:)










He gave an awesome mirror finish to the face of the heatsink. Just amazing work.





After that he packaged it up and sent it back to me. Thanks Jay.:beer:


Two days later I got it in the mail. First thing I did is put in the module and lens with no diode just to get a picture of what it looks like. I was so excited. This is the best part of this hobby. Figuring out how to make something that you have not worked on before is a great thrill.

Talk about :horse:

I opted to go for a copper module in this unit.:evil:












I spent a lot of time debating what driver setup I would use. I was going to use two Flexdrives in parallel but I decided to go with the Flexmod P3 from the good Dr. for this build. It is something that you don't see in portables and thought it would add a bit of a unique touch to this build. It is a linear driver that can give an output of up to 2A.






I won't go too heavily into the setup of the driver. If you want to know more you can see my tutorial. Click on the picture below to go to the tutorial.


Here is how the driver is set up.

How to set up the P3 for a handheld laser






I have taken the driver heatsink and extended it so it can be attached to the bottom of the host heatsink. I used three strands for each pin with the pyro wire that(according to Flaminpryo's lip test:p) can handle 5A. When tested it did not get hot so I think that it is OK.;)








Here is the driver. Since the primary use of this driver is for lab units and projectors I used a LM3805 on a second line in from the battery which drops the voltage to make a 5v signal wire to the modulation input that turns the unit on to full power all the time. There is very little current drawn from the Modulation input it should not need any heatsinking on the LM3805. I ran a wire from the positive in to the interlock to keep it on and I also disabled the 7 second delayed start by soldering two of the pads together on the driver.









I then soldered the diode to the wires.









I am going to bond the drive sink with the host sink(see yellow circles) with thermal epoxy.









If you look to the left of the yellow star I tried to start a hole with my Dewalt drill but that was not going to happen. I guess just thermal adhesive will be good enough.







Here it is. I have set it to 1.6A. Since it is a linear driver you can see an accurate current reading on the power supply. I will also be using the 3X18650 Lifepo4 high discharge batteries in series. It needs to be over 6V so three of these batteries are 3.2V(3.6V fully charged) each and in series will be will be between 10 to 11V.











The seller of these Lifepo4 says the battery elements have a 17A discharge rate. Should be enough.:evil:





So I charged them up. Check out the charging setup. They require a special charger that can handle batteries that have a low resistance in the cell and a cutoff of 3.6V. This batter holder makes a great charger unit as well. Just used some magnets and works great.










When the batteries were done charging I retested the unit to see if there were any differences when I switched from the power supply.









I set the two sinks together and let the thermal adhesive set.










I pinched the negative wire between the host heatsink and the lip that it sits on and tightened the stainless steel retaining ring down. Then I packaged the driver in the head. Oh yea, fits like a glove.:)









I tested the unit again using the host body as the ground to make sure I had a good contact.









I did a 60 second run with my finger on the driver heatsink that is now bonded to the host heatsink. It got warm but not hot. Yea!!! It is distributing heat into the large host heatsink very effectively.


Next I glued a spring that I got out of a $1 ebay flashlight on the bottom of the driver to make contact with the positive contact point in the host. Knew that flashlight would come in handy.:)









I soldered the positive wire to it and was ready for the final step.









Then I screwed the head into the host body and whala it is alive.:drool:
I now have an amazing host with a unique driver running a 445 @ 1.6A putting out 1870mW in a portable unit.:bowdown:



Beamshots
This thing is so bright. It is by far the brightest beam I have ever seen. I am in awe every time I turn it on.








































LPM Test:evil:

-----------------------EDIT---------------------

I got a bug to mess with my Frankenstein today. And as you all know I am never satisfied. And probably will not be till I actually kill a 445 diode. Which with all my high powered units none have died or shown any degradation yet. This diode has run for almost 4 hours now @1.6A but I have decided to turn it up a bit. It is now set to 1750mA.:eg:















The line starts here for 2W handheld 445's.:p





-------------------EDIT---------------------







405-G-1 Lens 1871mW!!!!




This is awesome. It runs better than I even imagined. High power and no overheating. I am so excited I am like a kid on Christmas morning.:san:


Here is a video of the unit burning a CD Case.







14 minute run I was not happy my new camera decided to stop recording at 14 minutes. I was going to start it back up but figured this gets the point across. I believe that it could have gone twice as long.





this time I set to HD setting instead of SD that it was on last time and it cut out at 7min. So I went and read my owners manual.(come on who reads the owners manual) and it say all files are limited to 2gb with the uncompressed video this thing saves in. Why can't it use X264 or something that can give great compression and excellent video quality. It is a scam I say. Anyway here is a 7 minute run but you can see the meter.:beer:









In conclusion. This is the most gratifying project that I have worked on yet in my small time in this hobby. This unit is so unique an such a ridicules power that I am sure it will make some heads turn. I have run it as long as 6 min now and it seems like it has not even got warm. I also noticed on this unit that the power does not drop as rapidly as with my other high power builds. It could be the linear nature of the driver as well as the massive heatsink.

Anyway I know you enjoyed this one. Probably not as much as I but that is the way it goes.:p
 
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jayrob

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Re: Ultrafire RL-2088 1300 lumen flashlight

I prepared some comments ahead of time after you showed me some of your previews of this epic build...

By the way, I have modified a nice kit for a 'drop in' style FlexModP3 with this host now... :cool:

http://laserpointerforums.com/f64/fs-rl-2088-frankenstein-kit-flexmodp3-66330.html


Wow that thing is awesome…

I thought you were going to use two FlexDrives wired parallel and heatsink them to the back of the main sink like we had talked about. And then use the 3 X 18650’s in parallel for a huge capacity…

But seeing your power measurement video, and how stable that bad boy is, says it all…

DTR Frankenstein… classic!

That thing is the most stable 445 hand held I have seen, and at that power, it is unbelievable!

I like your innovative driver modification for heatsinking it to the main heatsink of the laser…

I also love the thick stainless steel retaining ring on that host.



That thing is a laser cannon! :cool:

The size is gnarly…

I really like the root beer can comparison shot. That build also has multiple uses! If you ever have to park on a steep hill, it would make a good wheel chock! :crackup:

Probably make a pretty good boat anchor too…

All kidding aside, that is one awesome, epic, jaw dropping build man… :gj:

In your CD case burning video, it’s like that CD case isn’t even there!
 
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DTR

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Re: Ultrafire RL-2088 1300 lumen flashlight--DTR Frankenstein

Thanks Jay for all your assistance on this project. Could not have done it without you. :thanks:

This thing is more than awesome than I thought it would be I can't even describe in words the joy I feel. Like I said in the review I feel like a kid on Christmas morning that got the one thing he wanted the most and then finding out it is better than he thought.:D:D:D:D:D:D:D:D:D:D
 

weeba2kv

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Re: Ultrafire RL-2088 1300 lumen flashlight--DTR Frankenstein

OH MY GOD how perfect A+
 

Trevor

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Re: Ultrafire RL-2088 1300 lumen flashlight--DTR Frankenstein

Wow, that looks amazing. I'd love to play with some beam combination optics in that host... :eek:

-Trevor
 

cd520

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Re: Ultrafire RL-2088 1300 lumen flashlight--DTR Frankenstein

AWESOME PERIOD!!!! Thanks for the teaser last night hehe. I want one. I would really be interested in seeing how long it could run.
 

DJNY

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Re: Ultrafire RL-2088 1300 lumen flashlight--DTR Frankenstein

Day of the Deal 4?

I´M IN!!!! :D
 

DTR

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Re: Ultrafire RL-2088 1300 lumen flashlight--DTR Frankenstein

Day of the Deal 4?

I´M IN!!!! :D
:crackup::crackup::crackup::na::na::na::p:p:p

Sorry to say, never going to happen:beer:
 
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yobresal

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Re: Ultrafire RL-2088 1300 lumen flashlight--DTR Frankenstein

Holy catfish!!!! What a beast. Very nice build!
 

ElektroFreak

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Re: Ultrafire RL-2088 1300 lumen flashlight--DTR Frankenstein

freaking awesome!! Nice work!
 
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Re: Ultrafire RL-2088 1300 lumen flashlight--DTR Frankenstein

My...Chuck!!

So... when are you coming to Argentina again? :p

Will you ever try pushing it harder?
 

DTR

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Re: Ultrafire RL-2088 1300 lumen flashlight--DTR Frankenstein

My...Chuck!!

So... when are you coming to Argentina again? :p

Will you ever try pushing it harder?
I was originally going to put 1.7-1.8A into it but I want it to last so 1.6A it is. Above 1.6A you start to see less efficiency and the extra current is going somewhere most likely causing damage to your diode over time. I have used it for at least an hour so far and no degradation yet.

The raw output is still nice and clean.
 
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DJNY

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Re: Ultrafire RL-2088 1300 lumen flashlight--DTR Frankenstein

There should be enough space for correction optics right?
 

jayrob

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Re: Ultrafire RL-2088 1300 lumen flashlight--DTR Frankenstein

I was originally going to put 1.7-1.8A into it but I want it to last so 1.6A it is. Above 1.6A you start to see less efficiency and the extra current is going somewhere most likely causing damage to your diode over time. I have used it for at least an hour so far and no degradation yet.

The raw output is still nice and clean.
At 1.6 Amps, using a linear driver, I believe the current draw from the batteries is the same...

So that means that even though you have the 3 X 18650's in series, you can still get over 1 1/2 hours run time between charges if you use AW 2900 mAh batteries...
 

DTR

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Re: Ultrafire RL-2088 1300 lumen flashlight--DTR Frankenstein

At 1.6 Amps, using a linear driver, I believe the current draw from the batteries is the same...

So that means that even though you have the 3 X 18650's in series, you can still get over 1 1/2 hours run time between charges if you use AW 2900 mAh batteries...
I am going to stick with the LifepO4 batteries. I have not recharged them yet and have run it for at least an hour. The other thing is the more Voltage you pump into this driver the hotter it gets. The LifepO4's give a max of 10.8V fully charged where typical Li Ion's would give 12.6 fully charged.


The one thing that I really like about the Linear driver is at least I think it is contributing to the more stable power of this unit. My 1.6W builds with the Flexdrives drop power very quickly. The massive heatsink and copper module may have something to do with it as well.:D
 

jayrob

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Re: Ultrafire RL-2088 1300 lumen flashlight--1871mW 445 DTR Frankenstein

Yeah it's pretty incredible how stable it is...

And for over 5 minutes!

You say it isn't even warm after 5 minutes?
 




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