A pelican M6 head and reflector were significantly modified to house two Luxeon
1 watt LED's in a flood /spot selection and hosted on a SureFire L1:
The LED's could not be mounted on heat sinks in a conventional manner so over
10 carats of diamond powder was mixed into a very thick bog with epoxy. This
bog or putty was spread from the heat sink slug down over the rear of the LED's
and onto the Al surface. The bog was also used to mount the SPDT toggle switch
onto the back side of one of the LED's. Not evident in the photos, a wire frame stand
off was placed between the LED slug and the switch to allow for .030" of bog
between them. Some component and assembly photos:
An adapter collar which mates the PM6 head to the L1 also has a milled fork for
actuating the toggle switch. This adapter was threaded into the PM6 head and
then the reflector and electronics were loaded. The head rotates relative to the
adapter for switching from the flood beam on the side to the spot beam from the
front. Both LED's have a low and high luminous output due to the circuit within
the L1. The head can be felt to get warm in a reasonably quick fashion which
hopefully indicates that the diamond bog is a sufficient, if not ideal, thermal solution.
The side mounted LED was seated in and bonded with a clear epoxy that overlaps the
base of the lens. Only the lens is exposed to the environment and with the O-ring
placements, this light should be sealed from normal exposure to water and rain.
