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Sanwu Pocket laser extended double battery mod

Nutball

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I didn't get my pocket laser for burning, but I figure while I have it I might as well do some burning. I have found, especially when the battery has just a little use on it, the wide spread dot when viewed through the glasses at full power starts bright, but quickly dims to seemingly half or less power. I got some efest batteries, the best I know of. I don't know how they compare to high output batteries used in RC stuff (the kind of lipos I'm used to big or small), but either way it can only get better by doubling the battery power.

So, I'd like to look into the potential cost and feasibility of this project by hearing from you experienced builders. I'm super cheap, and have little idea about what effort and cost is involved in such a mod with likely the most expensive part being the stainless case extension, so lets talk design, and maybe make offers on the job. I don't think costs should be hidden in PMs if that is the general assumption...or rule.

I drew a design idea of mine. It shows the case extension to fit one more battery, with the 1mm diameter total extra clearance around the batteries, hopefully a paralleling case with insulator tube will fit inside. The paralleling case is drawn large with batteries and red and blue indicating the metal positive and negative jumpers. Also a miniature version in more natural colors is below with the insulating tube. Rivets of some sort might be used on the very ends to both attach the metal jumpers, and connect them to the battery ends.

I couldn't imagine a .5W pocket laser doing .5W for more than a split second before dropping to maybe 150mW. I haven't actually measured what mine peaks at and drops to over 5 seconds.
 

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BobMc

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Interesting idea :thinking:

I'm thinking Lifetime17 would be the "go to guy" on something like this?? Bet he could make you a solid battery tube that used your existing switch, so all you would have to do is swap battery tubes. If you go that route please make a post I just might like one or two myself. Good idea. :)

http://laserpointerforums.com/f52/over-1watt-sanwu-pocket-100828.html

It's a special build, but it a little powerhouse. (Don't know how long she maintain over 1 watt but it's something I should test)

Edit; on second thought he might not be able to use the existing switch, (because of the increased current and the two batteries being in parallel) but it's something I'd run by him? :)
 
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Nutball

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Well I have a 250mW, and I assume the .5W has the same switch, and I never feel heat from the switch, and I have a feeling even a tiny switch would have enough metal contact to withstand 1A, so that would support a few W, so the switch shouldn't be a problem, but good thinking ahead.

I just hope the mods would all fit in a case the same OD as the lens cap and switch to keep the smooth look. Otherwise I might as well just put the little laser module in a different host.

I hope this would be a cheap enough and desirable enough mod for it to be worth it to the builder to make many to keep cost down, and sell the rest to others. Theoretically you could connect two sets of modification parts to have a long pen with 4 batteries, that could make for a solid powerful .5W pocket laser. The duty cycle might change since Sanwu might have gotten their ratings from real tests with the recommended battery with its voltage drop over 40 seconds.

I just thought, the threaded connection point of multiple battery tubes could be too tight a diameter fit, so a single tube for 2 and 4 batteries is probably the best way.
 
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BobMc

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Well I have a 250mW, and I assume the .5W has the same switch, and I never feel heat from the switch, and I have a feeling even a tiny switch would have enough metal contact to withstand 1A, so that would support a few W, so the switch shouldn't be a problem, but good thinking ahead.

I just hope the mods would all fit in a case the same OD as the lens cap and switch to keep the smooth look. Otherwise I might as well just put the little laser module in a different host.

I hope this would be a cheap enough and desirable enough mod for it to be worth it to the builder to make many to keep cost down, and sell the rest to others. Theoretically you could connect two sets of modification parts to have a long pen with 4 batteries, that could make for a solid powerful .5W pocket laser. The duty cycle might change since Sanwu might have gotten their ratings from real tests with the recommended battery with its voltage drop over 40 seconds.

I just thought, the threaded connection point of multiple battery tubes could be too tight a diameter fit, so a single tube for 2 and 4 batteries is probably the best way.
Never hurts to ask, this hobby is always looking for new and fun stuff. :)
 

Encap

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Well I have a 250mW, and I assume the .5W has the same switch, and I never feel heat from the switch, and I have a feeling even a tiny switch would have enough metal contact to withstand 1A, so that would support a few W, so the switch shouldn't be a problem, but good thinking ahead.

I just hope the mods would all fit in a case the same OD as the lens cap and switch to keep the smooth look. Otherwise I might as well just put the little laser module in a different host.

I hope this would be a cheap enough and desirable enough mod for it to be worth it to the builder to make many to keep cost down, and sell the rest to others. Theoretically you could connect two sets of modification parts to have a long pen with 4 batteries, that could make for a solid powerful .5W pocket laser. The duty cycle might change since Sanwu might have gotten their ratings from real tests with the recommended battery with its voltage drop over 40 seconds.
You have a $50 250mW red Sanwu pocket model --right?
How much would you expect to pay for the mod you suggest if it could/would work? $50, $75, $100??

Have you found a "paralleling" case for 10440 batteries? If not are they available at all?

Doubt it would make sense for a builder to make more than 1 without any orders for same--is a bit too speculative and eccentric a thing.

A Sanwu pocket laser is what it is. Making it 2x to 4X longer defeats it's design and style "smallest" and purpose.

Realistically, how many would buy a Samwu "Pocket" with or buy the mod when a much better choice is a different model of small laser like Guardian which is only 3mm longer X 11mm larger diameter using a 18350 battery and can be 1W or 2W 445nm at only a $50 more than a "pocket" .5W 445nm--if you only want 500mW Guardian am sure Sanwu can make it that as well.

I would guess making one before making more would be the only wise thing to do if it can be done the way you suggest.

Duty cycle of the pocket model is limited by the small diameter host.

Maybe hook up a power source and run it for as long as you imagine you want it to run to see if it can handle same would be a good idea before you go doing a mod that will still be a 40 seconds on duty cycle--easier just to carry a spare battery.
 
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Nutball

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I thought about that stuff too. I paid $97 for my laser, goggles, and $17 shipping. It's a cool idea to expand the pocket laser, so I could see people buying the mod, but again it defeats the small purpose as you said. It would be a just for fun mod for those who already have pocket lasers, and want more power and run time. There is the customs risk and cost of buying a brand new bigger laser.

I've thought about an external battery upgrade, but can't think of a good way of doing it. I figured a modification to my laser would be more cost effective than selling it and buying a new or used bigger one, when I'm only a bit of battery power away from the burning power I like.

I really like the pocket laser's look and diameter, but personal preference desire's a longer pen more like the silver series. If I wanted small, I'd want a flat and wide keychain type that could take high discharge flat lipo cells that could easily support a few watts for a few minutes.

I guess I would settle for something fat and stubby that takes a case of 4 batteries in a square, but then I'd prefer a same diameter lens holder, and a side power button. Obviously I could then use a bigger battery, but then I'd be buying more batteries instead of using what I have.

I don't know what to do
 

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Nutball

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It burns well enough even if the burn power is minimal after a few seconds, so I guess I'll get a bigger one if I really end up needing more power. I mostly use it for pointing anyway
 




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