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C-Mount Red Mag Stubby Build...

jayrob

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C-Mount 2 Watt Red Mag Stubby Build...

This is my C-Mount 2 Watt Red build using one of the new diodes that Angelos (lazeerer) sourced...

Relative threads:
http://laserpointerforums.com/f50/testing-new-650nm-660nm-5w-diode-82919.html
http://laserpointerforums.com/f42/2-1w-evil-shadow-650nm-c-mount-diode-build-handheld-83267.html
FS: 5 Watt C-Mount Red Diodes with FAC from DTR (get one while they last)






I wanted these features for this awesome C-Mount red diode:

* Hand held
* Ability to focus
* 2 mode output
* Good battery capacity







About the cost of the C-Mount kit. See here: (there are options to save on cost as well - send PM!) :beer:





Heatsink/Driver/Lens:

The bulb stem is removed from the stock Mag to allow a good sized heatsink to be fit...




For now, I'm using a 3 Amp AMC7135 driver configured for 2 modes.

The driver must be thermal glued, but electrically isolated because the outer ring is negative, but the diode is case positive.

This is a V2 AMC driver that uses 8 X 380mA chips vs 350mA chips. (so it puts out 3 Amps)

Angelos is working on a similar driver, but will be designed specifically for heatsinking to a case positive build.

So I just may swap out this driver when he is ready! (maybe go for 3.5 Amps)

Update: I noticed the output power was dropping fairly fast on high mode, and after a discussion with Angelos about this, he told me that he had the same issue with AMC drivers unless they were heatsinked well... (thanks Angelos)

So I did this: :D



Now it's nice and stable at 2 Watts... :)

What an awesome diode!

I can tell you that this diode is rock solid and does not drop in output like a 445.

That said, I did not test over 1 minute at 2 Watts. But with a 445, you can almost immediately notice how heat sensitive the diode is...






For the lens, I'm using the same 50mm focal length lens that Angelos recommended:
Thorlabs - LA1213-A N-BK7 Plano-Convex Lens, Ø1/2", f = 50.0 mm, AR Coating: 350-700 nm

For mounting it, the lens fits perfectly into a 1/2" drilled hole that you can just also drill a smaller diameter hole after that, so that it creates a lip for the edge of the the lens to sit on...

So then I made a thin walled tube to hold the lens in place, and just simply used Silicone to secure it at the opposite end of the tube as shown. (I love Silicone)



This method allows me to be able to easily remove the lens in case I ever need to... :cool:






Switch Prep/Case Positive:











Other Details:

I wanted to be able to turn the head to adjust fine focus, but since I do not know how to machine/match the threads on a Mag, I had to thermal glue the machined down 'thread sleeve' into my custom head...

This is what is left of the stock Mag head after I machined it down to save the threads in the form of a 'sleeve' that I could thermal glue into my custom head.









Exit aperture...

I like to have a dust cap for my lasers, so that's all the AixiZ lens barrel and focus ring is for.



I had to bore it out larger for this wide beam to come through clean...






Output Power/Build Notes:

Linear driver - 2 mode configuration...

I tested current output to an XML emitter between the driver and emitter to make sure it was working properly.

It puts out the same to the emitter as it draws from the battery. Which it should. (linear driver)

* Medium mode - 945mA / 670mW's. :) (I was surprised at the output at 945mA's)
* High mode - 3 Amps / Just over 2 Watts.

Using a 6000mAh 32650 cell, it will have good run time between charges...






Concluding Thoughts:

I suppose this is a fairly conservative setting for this diode. But personally, I am satisfied knowing that it is happy in there. :)

Don't want to push it to the max in a hand held with no active cooling. Plus the supply/run time consideration...

I'm very happy with the way it turned out!

Hope you like it! :beer:






PM for kit... :D

This is my first C-Mount kit...

It brought back that feeling of 'new discovery' in building again. :cool:

It's an amazing diode!

About the cost of the C-Mount kit. See here: (there are options to save on cost as well - send PM!) :beer:

Even without the full custom head shown, I can still make it focus-able with the stock Mag head like so:









Adding Some Beam Shot Comparisons:

Comparing the Red C-Mount beam to a Mitsubishi 638nm build which is at 600mW's...

Note: I have the C-Mount adjusted for best beam focus. At distance, the Mitsubishi has way more divergence. But the C-Mount with FAC ends up with a nearly square dot as Angelos showed here:
http://laserpointerforums.com/f50/testing-new-650nm-660nm-5w-diode-82919.html#post1194069

You can see the Mitsubishi has a lot of divergence just by looking at the 'edge' of beam pictures below... (and especially in the distance shot at the bottom)

Two sets of comparison pictures because I have two modes with my C-Mount red build: (garage beam shots with smoke)







High mode - 2 Watts:









Medium mode - 670mW's:








Last but not least... :cool: (as you can see in this comparison with the Mitsubishi 638, the C-Mount with FAC makes a nice beam!) :D












Click here to see my list of projects and tutorials! :)

 
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Speedy78

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Woukd love to see some lpm graphs. Its nice to see some of these diodes making it out to the community. I wish I could drive one at 5W in a hand held!
 
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jayrob

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Angelos showed some really good videos of the output power in those threads linked.

He was also controlling the diode temperature for stable output...
 
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benmwv

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This is awesome jay.

I think you should try mounting a fan in a mag host. The fan could mount directly on the back of the heatsink, with a ring of small holes that come out the front. Holes drilled through the host wall right below the heatsink for intake. You can get some really small fans too. Search sunon fans on mouser.com to see them.
 

jayrob

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This is awesome jay.

I think you should try mounting a fan in a mag host. The fan could mount directly on the back of the heatsink, with a ring of small holes that come out the front. Holes drilled through the host wall right below the heatsink for intake. You can get some really small fans too. Search sunon fans on mouser.com to see them.

If the driver gets warm, it drops in output power. (good quality cell needed too)

I'm going to do a little more testing...

Update link! :) (added to OP)
 
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grainde

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Great work, I really like your maglite builds! :)

Just a thought, if you wanted to up the power you could always add a couple of extra 7135 chips. I the runtime will probably suffer as you mentioned the diode is very sensitive, but I guess itll depend on what youre after? Personally Id try 2 or 3 chips in the hopes it might reach 2.5 ish W, :eg: but then I often only run my lasers for a few seconds at a time.

Anyway I guess you will have already seen this, but here is a thread on adding the chips just in case.;)

+1 and :beer:
 

jayrob

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Great work, I really like your maglite builds! :)

Just a thought, if you wanted to up the power you could always add a couple of extra 7135 chips. I the runtime will probably suffer as you mentioned the diode is very sensitive, but I guess itll depend on what youre after? Personally Id try 2 or 3 chips in the hopes it might reach 2.5 ish W, :eg: but then I often only run my lasers for a few seconds at a time.

Anyway I guess you will have already seen this, but here is a thread on adding the chips just in case.;)

+1 and :beer:
About the diode, Angelos told me that it is sturdy and stable. (I believe him)

I tested my current drain, and the driver gets a tad warm, and will drop in output.

But it's not a bad problem, just need to pot the driver a little better is all... :)
 

grainde

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Ah ok so you should be ok if you improve the heat sinking on the driver then?

I did this to a Poppas I modded:



The light is stable at 3 A and doesnt dim. Heres the thread if youre interested. :beer:
 

jayrob

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Ah ok so you should be ok if you improve the heat sinking on the driver then?
Already have it all apart and am planning on that same thing...

I'm going to put a round copper heatsink so that it can thermal glue to all chips on the one side, and then also do something similar to the chips on the other side...

Edit: Done! :D

Update link! :) (added to OP)
 
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LKY2009

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Nice job Jay! Would like to see some more shots of the beam when your finished testing. Also would like to see how you went about mounting the lens in there.

+Rep
 

jayrob

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Nice job Jay! Would like to see some more shots of the beam when your finished testing. Also would like to see how you went about mounting the lens in there.

+Rep

More beam shots added to the OP... :beer:





Update: I noticed the output power was dropping fairly fast on high mode, and after a discussion with Angelos about this, he told me that he had the same issue with AMC drivers unless they were heatsinked well... (thanks Angelos)

So I did this: :D



Now it's nice and stable at 2 Watts... :)







For mounting the lens...

It fits perfectly into a 1/2" drilled hole that you can just also drill a smaller diameter hole after that so that it creates a lip for the edge of the the lens to sit on...

So then I made a thin walled tube to hold the lens in place, and just simply used Silicone to secure it at the opposite end of the tube as shown. (I love Silicone)



This method allows me to be able to easily remove the lens in case I ever need to... :cool: (adding this updated information to the OP)
 
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nueces

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Sure is nice to be able to watch a master at work. :bowdown::bowdown::gj:
 

jayrob

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Sure is nice to be able to watch a master at work. :bowdown::bowdown::gj:

Glad you like it!

Thanks to everybody for the props!

But especially to Angelos for sourcing these awesome diodes, and then finding a good lens, testing the diodes, and then showing us how we can do our own builds...

Angelos you are the man! :beer:

:thanks:


I'm very excited about this build... Haven't been this pumped about a new build in a long time. Awesome diode!
 
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DTR

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Nice work Jay. Amazing build.:beer:
 

Wolfman29

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Who designed your heatsink? I may need one for a build I am planning.
 







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