DIY P60: Difference between revisions
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==Finishing up== | ==Finishing up== | ||
[[File:P60-positive.jpg|thumb|The bottom of the driver with the small spring in place and two solder bridges from the driver to the pill.]]If the LED is working, you can go ahead and solder the driver board to the pill. This isn't easy to do because the pill will soak up the heat from the soldering iron. It is easy to get a blob of solder on the outer ring of the driver, but harder to bridge over to the pill. However this is essential, not just to hold the driver in place but to complete the path from the negative end of the battery, through the switch, up the metal body tube of the flashlight, to the pill, and to the driver via the solder bridge. Try to get two good solder bridges in place. Use your DMM to make sure there is continuity between the pill and the outer ring of the driver. If there are any spikes sticking out of the side of the pill, you can file them down. | [[File:P60-disk.jpg|thumb|left|The isolation disk placed over the LED to prevent the reflector from shorting out the LED.]][[File:P60-positive.jpg|thumb|The bottom of the driver with the small spring in place and two solder bridges from the driver to the pill.]]If the LED is working, you can go ahead and solder the driver board to the pill. This isn't easy to do because the pill will soak up the heat from the soldering iron. It is easy to get a blob of solder on the outer ring of the driver, but harder to bridge over to the pill. However this is essential, not just to hold the driver in place but to complete the path from the negative end of the battery, through the switch, up the metal body tube of the flashlight, to the pill, and to the driver via the solder bridge. Try to get two good solder bridges in place. Use your DMM to make sure there is continuity between the pill and the outer ring of the driver. If there are any spikes sticking out of the side of the pill, you can file them down. | ||
Usually you also need to attach the small spring to the bottom of the driver board. Put two blobs of solder on the outer parts of the center of the driver. Then put the spring in place and re-melt the solder. It is essential for the spring to be very secure. If it comes loose, it could cause a short between the negative and positive parts of the driver board. This would produce a dead short for the battery when the light is switched on, possibly causing a fire or explosion. Give the spring a good tug and check it from time to time as you use the light to make sure it is not coming loose. If you turn the light on and it does not light up, turn the light off immediately and make sure there is not a dead short. | Usually you also need to attach the small spring to the bottom of the driver board. Put two blobs of solder on the outer parts of the center of the driver. Then put the spring in place and re-melt the solder. It is essential for the spring to be very secure. If it comes loose, it could cause a short between the negative and positive parts of the driver board. This would produce a dead short for the battery when the light is switched on, possibly causing a fire or explosion. Give the spring a good tug and check it from time to time as you use the light to make sure it is not coming loose. If you turn the light on and it does not light up, turn the light off immediately and make sure there is not a dead short. | ||
With the spring in place, you can put an isolation disk over the LED and screw down the reflector. Since the reflector is made of conductive aluminum and would otherwise touch the two solder points on the LED board, the isolation disk is essential to avoid a short. Attach the big spring to the pill and screw the reflector down (sometimes the big spring isn't needed). Now you can put the drop-in in a light and see if it works! | With the spring in place, you can put an isolation disk over the LED and screw down the reflector. Since the reflector is made of conductive aluminum and would otherwise touch the two solder points on the LED board, the isolation disk is essential to avoid a short. Attach the big spring to the pill and screw the reflector down (sometimes the big spring isn't needed). Now you can put the drop-in in a light and see if it works! | ||