Remote P7 Battery Pack for 18650 cells Options

[pauly]

Most likely just some threadlocking compound that they've put on. It's a shame when they threadlock bits, it annoys those who want to tinker . Thanks for the update.
It's the front on the 5 mode that dictates modes, and the back on the 2 mode.

Ahh right, any idea how to free it up, I am going to use the one I can undo to convert to the battery pack anyway and use the one I can't on the bars as a backup, not that i have the bar one switched on anyway, If I have to get another I will get a two mode so I can mix and match, will do that when I order some more batteries.

[Jarl]

I'm not 100% sure what the pill looks like, but heat normally works a treat- hairdryers are good, or stick it in a plastic bag in boiling water. The hotter and longer, the better. A mug warmer, if you have one, is a very good thing to use. The LED won't get damaged by the heat because it's not on. Try not to heat it up or cool it down too quickly- this can cause thermal shock, cracking components on the PCB, though as long as you're letting it cool down naturally, it should be fine (i.e, don't douse it in cold water to cool it quicker!) Good luck!

[Liam]

Turboferrret - excellent groundwork and engineering going on there! good effort! I'd be interested in getting a set off you after I get my P7 from DX. As just an hour of use could be annoying! Keep us updated on the progress and testing!

[marcliam]

Turboferrret - excellent groundwork and engineering going on there! good effort! I'd be interested in getting a set off you after I get my P7 from DX. As just an hour of use could be annoying! Keep us updated on the progress and testing!

I've been watching progress on this with interest, great stuff, i'm inpressed!

So am I right in thinking that I could use this to power up my Airbike Everlight SL1 (see here)

[turboferret]

The prototype P7 torch fitting arrived yesterday, so here it is next to a standard torch



This one hasn't been anodised, the production ones will be black



Unscrewed from the head



With a 2fish lock-block onto the closest thing to a handlebar I had without getting cold going outside!



One issue I see is the balance point of the modified torch - previously using a lock-block you could velcro it onto the centre of the torch, now the centre is in fact where the little cooling fins are. I'll give this a good test and see if heat is a problem, but I'm sure other mounts would alleviate this issue.

Edit: didn't read replies before answering first!

Marcliam, the holder should be fine for your Airbike, but you'd have to make sure you had the right connector, both type, size and polarity - happy to supply a holder without a cable if you want.

Regarding the threadlock on the P7 torches, heat is your friend. I managed to snap the battery tube of my first P7 where the threads start, so brute force isn't the key! My 2 new torches also have very stubborn pills, which take a bit of time to remove. The basic P7 design doesn't have a positive stop for the battery tube, hence why it is glued in place, that seems to be the only reason I can see.

With my new 1:45m ish commute, 1 battery seems to last in my P7, but I'm sure there is some dimming which would be annoying off-road. 4 batteries certainly won't have this issue!

Cheers, Rich

[NickW]

Excellent work TF!

[Jarl]

With my new 1:45m ish commute, 1 battery seems to last in my P7, but I'm sure there is some dimming which would be annoying off-road. 4 batteries certainly won't have this issue!

You won't be doing your cells any favours by discharging them that low. A battery change halfway round wouldn't go amiss, and would greatly extend cycle life of your cells

Liking the look of the replacement tube . Looks like it wouldn't mind a bit of lube on the threads and O rings, though. I like my flashlights well lubed

[pauly]

Looking good to me, air flow over the torch should keep it cool even with that bit covered, I don't run mine on high when stood dtill anyway

[marcliam]

Marcliam, the holder should be fine for your Airbike, but you'd have to make sure you had the right connector, both type, size and polarity - happy to supply a holder without a cable if you want.

The Airbike has a 5.5 x 2.1 coax connector, which looks to be what you've gone for? So assuming polarity is right I would be OK.....

Can't help but think that there are quite a few people out there who have bought the Airbike light from on one or ebay who will be looking for extra / replacement batteries (if you want to increase your market size?)

[turboferret]

Guys,

It is with great regret that I will not be continuing to pursue the P7 adaptor concept

There has been overwhelming enthusiasm from MTB’ers all over the world, much more than I had envisaged when I started messing around with battery holders. I am very sorry to disappoint a lot of keen prospective buyers.

Let me explain - I had rather naively assumed that one P7 was the same as another, and I could produce a universal fitting to replace the battery tube. However, while they look the same from the outside, the internals seem to change quite frequently, which would at worst render the adaptor useless, or at best mean it would only fit a few torches. Trying to keep track of design changes and produce a guide of what torch a potential buyer has, and thus which adaptor is required, is beyond what I am willing to do. Given the potential for large numbers of returns on adaptors which won't fit, and the very small profit margin on each one, the chances of making a considerable loss are pretty high. I would also have to keep a fairly high inventory level of parts, and commit to fair sized production runs, so despite the provisional orders, the risk is high.

I will still be making 4 x 18650 battery holders, and pouches, suitable for DIY’ers or people wanting an external pack for existing lights, but not a complete system. I cast my first finished holder using my rapid prototyped mould, and it's excellent, fantastic surface finish and geometrically perfect.



If people want one of these, I'll be making quite a few, £12 + postage to anywhere in the world, let me know, will have them available very shortly in 4S1P, 2S2P or 1S4P.

Thank you to everyone for their constructive comments and useful input over the past month or so, it has been great to tap into a wealth of knowledge, ideas and experience. It has been great fun, and kept me amused for a good few weekends and evenings, but a number of variables seem to be conspiring against me. Sorry for letting you down.

Cheers, Rich

[Jarl]

I had a sneaking suspicion this might be the case.... I try not to touch screw threads with a barge pole, there's far too many variables. Still, at least the 4x holders are coming along nicely

[glynn six 0]

il also be interested in the battery holder.
would we order them thro this forum or to you direct?.............................great work by the way

[marcliam]

Yep i'm interested too, to put together a spare battery for my Airbike Everlight.

The whole concept of a standard but cutomisable 18650 holder in itself seems like a worthwhile project because nobody else seems to make one.

Out of interest, is your day job in product design and development or manufacturing?

[old dude]

nice work,
seeing that the p7 torches varies with different models, would it be an idea to make up some dummy 18650
batteries out of the resin ,so a length of cable could be attached to it,
then the diy'ers can drill a hole in the body of their own P7,pop in the dummy, and join it up via a quick connector to your battery pack,
just a thought! as it could solve the problem of running an external power supply and keeping the orginal switch
the dummy would take designing, as it would be a bit fiddly, as the cable would have to be threaded thro, the hole in the P7
then the dummy would have to squeesed past it over the cable !
would there be enough space?
i don,t know as i hav,nt got a P7 to look
just a thought.....
solutions appear easy, till you start to put them into practise
then one problem comes one after another!
still, very impressive work!! and certainly looks well
good luck with the project

[Jarl]

Interesting thinking old dude. IMO it'd be easier to drill a hole and solder to the + and - contacts, though.

[old dude]

you need to make diy projects accessible and do-able to everyone
as some people would`nt even have a soldering iron,
and there,s a little bit of skill involved
we have all got a bit of knowledge in most things but not all things
and probably doing a bit soldering would be a big task to some people
especially for the first time!

[turboferret]

Right, subsequent to the demise of the replacement battery tube I've decided to make an alternative.

There was quite a bit of interest in the idea of a nice simple 'dummy cell' concept for those wanting an external battery pack for the P7, and were happy to drill a hole in the side of their torch.

This will be a bit of a DIY solution, as you'll have to source your own cable, and either crimp or solder the ends, and of course drill your torch, but it should be a fairly simple solution which should be reliable and versatile.



That's the holder, and this is roughly how it'll go in a P7 (only with the wires meeting up of course!)



Price will probably be under a tenner, but not really decided yet.

I've updated my website and the ordering page will be up and running as soon as I've made a few pouches and cast a few holders - I'd rather people had to wait a bit to order, than wait to receive after paying!

My friendly rapid-prototyper is again providing amazing help, and I'd expect that I'd have the first dummy cells within a fortnight.

Cheers, Rich

[Gareth]

Rich, you are a marvel!

[Mick]

Rich, you are a marvel!

[turboferret]

Guys, quick update to say that I've been busy making lots of bits, and I'm ready to start taking orders.


4 x 18650 cell holders


2 x 18650 holders


single 18650 holders


pouches

Dummy cells will be available soon, the first mould didn't work out quite as I'd hoped, so it'll be a few days before I've got them sorted - 24 hour cure time on the silicon is a bit of a drag...

Turboferret

I might not be able to quite meet initial demand, but I've made a bit of stock, so hopefully orders won't take too long to be completed.

Cheers, Rich