9mm 445nm 2D Maglite Build [COMPLETE]

[Photonz]

Build is Complete! :wave: Check Page 2!:wave:



So I recently ordered a 2D Maglite from Mrcrouse and felt like documenting the long journey that is the building process.:wave:

My plan is to build one of DTR's 9mm diodes with an x-boost set at 1.8A into one of Mrcrouse's 2D Maglite hosts. Because I am sort of limited with battery options with an x-boost and the size of the host, I decided to make a homemade, makeshift battery spacer

There are pictures below. The purpose was to hold a quality 18650 cell in the space that two D Cells would occupy.

Here it is with the 18650 cell inside

One last picture for diameter comparison

I will be updating this thread periodically as I get more stuff done/receive parts etc.

Update: Here's the x-boost driver set at 1.8A that I plan to use. I've placed it between two copper heatsinks to keep that baby cool

Thanks for looking:beer:

 

[COMMANDR]

Re: 9mm 445nm 2D Maglite Build

Plenty of room to work inside that Mag. Get us posted.

 

[Livinloud]

Re: 9mm 445nm 2D Maglite Build

If you havent built it yet then take one of those copper heat sinks off and thermally bond it to the inside wall of the maglite. Use the whole host as a heat sink

 

[The Lightning Stalker]

Re: 9mm 445nm 2D Maglite Build

Yeah, that won't be enough to sink away the heat. It should be bonded to the back of the big heatsink or
something else that has high mass AND makes good contact with the host body to get a decent runtime.
A small heatsink like that will get hot inside the host and give no indication of the temperature to the
outside world.

 

[Photonz]

Re: 9mm 445nm 2D Maglite Build

Thanks Livinloud and LightningStalker, I didn't think that of that. Will make sure to attach one to the host:beer:

 

[Livinloud]

Re: 9mm 445nm 2D Maglite Build

I meant back of heat sink......thats what I did with mine. I think jayrob puts them on the host but I went with back of heat sink. That thing is massive so it can handle having the diode and driver sinked to it

I have a photo on my phone if you want to see how I did mine. You need to add leads from the diode to the driver but thats easy

 

[Photonz]

Re: 9mm 445nm 2D Maglite Build

I know what you mean, don't fret I should've been more specific. When I say, "attach to the host" i mean I'll make sure the heatsink is physically connected to the host (i.e. the heatsink) so heat can flow out of the smaller heatsink into the actual heatsink/host.

 

[Thejoker301]

Re: 9mm 445nm 2D Maglite Build

It seems the driver is not really connected to the Copper heatsinks. As said above ^^ use a thermal compound adhesive and bond them thermally.

:beer:

 

[Livinloud]

Re: 9mm 445nm 2D Maglite Build

Arctic Alumina or whatever its called, pick some up to bond the driver to the heat sink. I doubted that stuff at first but DANG, it is permanent! You have to break the driver to get it off my heat sink, plus it has thermal properties to transfer the heat from the driver to the heat sink

FYI in case you've never used it before, the instructions say work quickly or it dries on you......by work quickly they mean you have 1-2 minutes if not longer before its hard as rock. I sat there for 2 minutes holding the driver to my heat sink and it didn't bond yet. About 3 minutes after mixing it was bonded. Oh well, rushed for nothing the first time

 

[The Lightning Stalker]

Re: 9mm 445nm 2D Maglite Build

The only way I've found of removing it is to press a razor utility knife between the heatsink and whatever it's
bonded to. I was also reading on some overclockers forums that you can mix it with a little of the regular
thermal compound to make it easier to remove.

 

[Photonz]

Re: 9mm 445nm 2D Maglite Build

I now have the diode module's leads soldered to the driver and ran some tests with the 1.8A x-boost off my best 18650 cell and got an output of 1.5W with my Radiant X4.

I'm guessing the LPM doesn't heat up fast enough to properly get an accurate reading and I'm using a 3 element glass lens which will decrease the output. I may get the laser remeasured sometime by someone with an Ophir sensor on the forum but I first must finish the build.

Here's the pic

 

[Wmacky]

Re: 9mm 445nm 2D Maglite Build

After about 30 Seconds the radiant should be accurate enough.

 

[Photonz]

Re: 9mm 445nm 2D Maglite Build

I think it may be the rate of change in power that is throwing off the LPM reading. The TEC based LPM's cannot keep up with the rate of change in power for laser's like this one thus they produce inaccurate readings.

 

[Wmacky]

Re: 9mm 445nm 2D Maglite Build

Why is it changing power so rapidly? Are you testing the module without a heat sink? My 445 seems rock solid at around 2800 while well sinked in the host. This with a 2.2 driver and using a radiant LPM.

I think it may be the rate of change in power that is throwing off the LPM reading. The TEC based LPM's cannot keep up with the rate of change in power for laser's like this one thus they produce inaccurate readings.

 

[Photonz]

Re: 9mm 445nm 2D Maglite Build

I don't know why. I test the module in a heatsink from an unused host and I set the driver on an even bigger heatsink (than in the picture) when testing. I know I'm losing some power with the 3 element lens but I wouldn't think THAT much power.
This is the 2nd time i've had issues with getting reasonable power from the 9mm 445nm diodes. Here is the first: http://laserpointerforums.com/f51/only-1-8w-3w-laser-89630.html

 

[Wmacky]

Re: 9mm 445nm 2D Maglite Build

I don't know why. I test the module in a heatsink from an unused host and I set the driver on an even bigger heatsink (than in the picture) when testing. I know I'm losing some power with the 3 element lens but I wouldn't think THAT much power.
This is the 2nd time i've had issues with getting reasonable power from the 9mm 445nm diodes. Here is the first: http://laserpointerforums.com/f51/only-1-8w-3w-laser-89630.html

You really need to get a G2 type lens for intial testing to get a base line. Did you ever get one? There was a recent post about ebayed G2 type lens going for $8 a pop. Also, My host is the massive MSSSW3. I'm committed to large "lightsaberish" type hosts on all my builds for rock solid performance. I don't care for the smaller pointer pens except for low powered diodes builds.