Red DIY DVD laser burner.

[photongeek]

[quote author=photongeek link=1181635652/105#109 date=1190038713]Ken:
As I am looking for ways to properly and passively cool this thing, I'm curious about your use of thermal epoxy. I take it that you are trying to transfer heat from the module to the board for additional cooling surface area? What if we drilled and tapped the bottom section of the module case and then drilled a hole into the Dorcy's head. We can then push a machine screw through the head hole and screw it into the module (without shorting the diode pins of course). This may permit heat transfer from the module to the outer flashlight body providing a much bigger surface area for the heat to dissipate. Possible? Do you see an electrical problem with this? Is the flashlight casing part of the circuit?

I would have to say that would work marginally. Anything we do is going to improve the performance. I don't know if I know for sure exactly what it is your talking about but if you want a cheap means of cooling the module you can do what stevetexas did and fill the head with solder. Drill a hole in the center for the module and your in great shape. I personally prefer the Spacers that have been fashioned for me to fill the head completely. Unfortunetly all teh spacers I've got have been spoken for so I don't have any spares.

[/quote]
What kind of spacers?

 

[Kenom]

they are made of aluminum. here is a picture of a module with a spacer.

 

[photongeek]

Thanks. That looks like it should help a lot.

 

[kdubbz]

hmmm I need to cool the module also, and kenom's alumnium spacer seems to be best. Does that spacer touch the inside of the flashlight casing? If so, how did you make that? Put the alumniun on a lathe?

 

[photongeek]

Well, that's it. The diode lasted about 5 seconds and then went dim. MAN that sucks!!! Ken, I never took so many precautions with an electronic project as I did with this and it still died. As I no longer have the patience to try again, I'll be putting up for sale, my brand new pair of Wicked RED Laser Shades and the new diode I just ordered from SenKat if anyone is interested.

 

[LarryQ]

PM sent.....

 

[Kenom]

If you would like, I will assemble and test the thing for you for a minor fee of $20 you pay shipping both ways. Keep the rest of your stuff and I will throw in one of my spacers ta boot. Now this will be only in a Dorcy Jr. so you'll have to buy one of those and provide to me as well as the module and diode. (essentially all your parts.) I won't guarantee it will work for more than a few weeks but for $20 you can't beat it!



I do have it touching the outside of the flashlight head although not tight. They were turned on a lathe yes. It's my ultimate goal to have custom heads designed with optics threads, hole for a diode and solid aluminum all the way around. Then I just need to screw in the new head with a diode and I'm rockin

 

[kdubbz]

AH HA! I figured out why mine wouldent burn well, I was focusing it wrong! I made it so theres a tiny dot at a few inches away, and it burns just like yours kenom. I am very happy now. THanks!

 

[trist-10]

I'm just curious, has anyone actually successfully fitted a capacitor into their dorcy jnr? If so, could you please provide a very basic diagram of exactly where it should be soldered, for dummies with very little knowledge in electronics like myself :-?
Cheers

 

[photongeek]

If you would like, I will assemble and test the thing for you for a minor fee of $20 you pay shipping both ways. Keep the rest of your stuff and I will throw in one of my spacers ta boot. Now this will be only in a Dorcy Jr. so you'll have to buy one of those and provide to me as well as the module and diode. (essentially all your parts.) I won't guarantee it will work for more than a few weeks but for $20 you can't beat it!



I do have it touching the outside of the flashlight head although not tight. They were turned on a lathe yes. It's my ultimate goal to have custom heads designed with optics threads, hole for a diode and solid aluminum all the way around. Then I just need to screw in the new head with a diode and I'm rockin

PM and email sent, Ken.

 

[trist-10]

Oh and sorry but one more question. How important is it to use thermal epoxy? Will normal heat resistant epoxy be fine? How hot should I expect the thing to get? Thanks

 

[morganclay1219]

Trist, if this would fit (I don't have tantalum capacitors so I can't really test the sizing), here's how to do it.  Solder the capacitor to the corresponding leads on the laser diode.  HEATSINK REALLY WELL while you are soldering to the diode leads.  You can use a heatsink clamp or alligator clips by putting the clip/clamp between the capacitor and the diode, and put the diode in the top of the module before you solder to help with heatsinking.  If you've read Daedal's driver post, you will know that soldering the capacitor directly onto the LD leads is the safest way.  Again, I'm not sure how well this would work because of size, so please let me know how it does because I want to do this myself.  Good luck! [smiley=thumbsup.gif]

'Eer

p.s. Rog, I stole your diode-removing picture. Hope you don't mind ;D

 

[morganclay1219]

Sorry about that, I accidently hit post twice, deleted the second (which deleted the pic from both), and can't get the pic back on, so here it is.

 

[morganclay1219]

And now it's back in both... Crazy forum

 

[kdubbz]

Damn, I just burnt out my 2nd diode. This one lasted about 25 minutes total run time since its been installed, and it died. I guess It just cant handle the power from the batt and the resistor, looks like ill be ordering 2 more diodes and getting a cap installed. Radio shack sells this capacitor correct? I was usuing it all of a sudden it went dim, turned it off, on again and it was bright then dim again and stayed dim. Checked connections all was well, O well I know the risks with diodes i blame myself.

 

[SenKat]

Damn, I just burnt out my 2nd diode. This one lasted about 25 minutes total run time since its been installed, and it died. I guess It just cant handle the power from the batt and the resistor, looks like ill be ordering 2 more diodes and getting a cap installed. Radio shack sells this capacitor correct? I was usuing it all of a sudden it went dim, turned it off, on again and it was bright then dim again and stayed dim. Checked connections all was well, O well I know the risks with diodes i blame myself.

Were you only using a resistor ? And if so - what value ? What types of batts ?