DIY 700 lumens dive light

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Joseph R.

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Location
Chandler, Arizona
I wanted to share my new DIY dive light.
My design requirements were:
-Compact (about the size of my UK SL4)
-Approximately 700 lumens light output
-Rechargeable batteries
-Muliti modes (High, Low and Strobe)
-2+ hours run time on high

This is my parts list based on my design requirements:
-1 3D Maglite and new o-rings
-3 CREE XR-E-R2 LED's
-1 Reflector from Deal Extreme
-1 14.8V 2400mAh Li-Ion battery pack and charger
-New battery and charger connectors
-Task-LED b-flex driver board
-Snap contact switch
-Aluminum, Delrin and Polycarbonate for custom parts
-O-rings

Custom parts that I fabricated:
-Polycarbonate lens .236 thick
-Main body
-LED heat sink
-Switch actuator and knob
-Charger connector cover
-Battery jumper
-Terminal block
-Driver board holder

I had to modify the Maglite head and DX reflector so every thing would fit.
See photographs below.
The light works great on land and I will take it diving in July!

Joe R
 

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cool!

how did you determine your lumen output? (taking the sum of the three LED emitters from the specs, or did you measure it).

how is the main body fabricated?

about how much did it cost to put it all together? (or a price breakdown)



cool light.

thanks. Mike
 
Nice work.

My guess if you estimated lumen as its not exactly easy to measure them aye! ( lucky for so many manufactures and their "claims")

Based on the LEDs, batteries and expected run time 700 seems about right for produced lumen but output will be less.

So how does the switch work?
Any beam shots? preferably with measurements of beam width and distance from wall.
 
Thanks for the complements.

Mike, the lumen output was determined using the LED specs.
The information I found on the internet for the R2 LED, is 220-290 Lumens at 1000ma.
But I'm not sure that's correct, because I was unable to find the specs on CREE's website. Packhorse is right, it's only an estimate.

Mike, the main body was fabricated from a 2.250 inch diameter piece of aluminum.

Here is an approximant cost breakdown:
-1 3D Maglite and new o-rings----$20.00
-3 CREE XR-E-R2 LED's----$7.00 each (Deal Extreme)
-1 Reflector from Deal Extreme----$7.00 (not sure of the part number. Deal Extreme website is down)
-1 14.8V 2400mAh Li-Ion battery pack and charger-----$75.00 for the battery $20.00 for the charger
-Task-LED b-flex driver board-----$30.00
-Snap contact switch----$2.50
-Aluminum, Delrin and Polycarbonate for custom parts-----$50.00 (I had some material at home)

Packhorse, the switch is a simple miniature contact switch. It's mounted in the rear cap and is actuated by an aluminum rod that has double o-rings and goes out the rear cap. To control the switch you turn the rod clockwise.

I will try to post some beam shots in the next couple of days.

Joe R
 
I have attached a beam shot of my new light against my Ikelite RCD.
The new light is on the left and is much brighter.
The distance from the wall is 180 inches and the hot spot on the new light is 32 inches in diameter.
This would make the beam angle about 10 degrees. The photograph was taken with an Olympus SP 350; ISO set at 50, shutter speed 1/4 sec and aperture set at 2.8.

Joe R
 

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