I'm almost ashamed to submit this after seeing some of the beautiful machined lights that some of you have built lately, but in the interest of the common folk who don't have a lathe... here goes.
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I had a little time over the holidays and decided to try something different. Having admired the simplicity of the lights I'd seen being built using copper tubing, I thought I'd try incorporating that into the design. The build is simple, but the copper adds about 30g to the weight of the light (compared to my all aluminum design). The heatsink fins are probably not necessary, but do add a nice look (subjective) and some additional cooling. I'll be posting build photos at my website soon.
The light is made from one inch square aluminum tubing and 3, 3/4" copper pipe end caps (they actually measure about 7/8" (22mm) ID. The build would not be hard at all if you didn't have to cut some length off of the copper caps. I've used Arctic Alumina Adhesive to attach the copper caps to the aluminum body. Time will tell if this holds up, but I have some other AAA'd parts that have held well, so this is sort of an experiment (aren't most DIY builds?). The heatsink fins (3/8" aluminum C channel) are AAA'd on as well, and I made two aluminum end caps for the aluminum body and molded some JB weld onto them so that they will fit into body and stay put with some silicone caulk. This will be a handlebar mount and I still have to make the bottom part to connect to the bracket that I am using.
The output looks about the same as my other Triple SSC P4 lights, bright, and a lot of light for the money.
Inside: 3x SSC P4 U-bin, 2x15 degree and 1x5 degree L2 20mm optic.
A 3023 wired Buckpuck @ 1A, with dimming (uses a 5k pot).
A standard Type M DC power connector is used.
14.8v, 4A Li-Ion battery pack.
My son came up with the name Copperhead. Time will tell if the AAA holds the copper caps onto the aluminum body. Since I'm planning this as a bar mount, it will receive a lot more vibration than a helmet mounted light.
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