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  1. Build #2 Progress, Jan 08, 2012 - Greasing the skids...

    Although my wife still thinks I'm making up that expression, that's exactly what's going on right now. Trying to get as much done as possible before I have the housings in hand. Mainly this involves prepping the Maxflex boards with mounting tabs and pre-soldering the LED power wires. Once the housings are here, the task of epoxying the LED boards to the housing begins, installing the switch in the lid, installing the battery power wire, then soldering everything together. The Maxflex itself ...
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  2. Build #2 Progress, Dec 23, 2011 - Making a List... Checkin' it twice

    Looking forward to celebrating Christmas this weekend!

    Finally got all my drawings finalized this week and in the hands of my machinist along with about 40 pounds of 6061 aluminum.
    Also received the Purchase Order this week from the plastics shop on the new version of the lens cover, so now it's just a waiting game till these new components are ready.

    All other piece parts are in hand... LED boards, Lenses, controller boards, batteries, connectors, chargers, ...
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  3. Build #2 Progress, Dec 23, 2011 - 2900maH Rundown Test

    Ok, after fighting with Christmas lights that never seem to want to work, it's nice to play around with a light that actually does what it's supposed to. Here's the run-down curve for the new 2900mAH pack paired with the DS-500 running on high (level 5) in steady mode. This is the classic lithium-ion discharge curve, although you can see a few things that are specific to this particular application.
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    Intially, the pack was fully charged at 12.57 volts. ...
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  4. Build #2 Progress, Dec 11, 2011 - Batteries-R-Us

    Got the new batch of batteries this weekend. Looking good so far. The triangular pack used to be 2800mAH Sanyo cells, but is now 2900mAH Panasonic cells. Got a few soldered up and ready for strain-relief and waterproof coating. I'll plan on doing a new run-down test with the taillight this week to compare to the previous results with the 2800mAH. Stay tuned.

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  5. Build #2 Progress, Dec 8, 2011 - Looking for one good CNC shop!

    OK, these CNC machine shops are bumming me out. It's taken three whole week for me to initially hear "Yeah, It looks like we can do your job at the desired cost," only to be followed up with "I don't think there's any way we can touch that price." SO, it looks like I'll be dropping back to plan B, which is to go back to my original in-town machinist and have a smaller quantity made in the interim, while I'm still looking for the right machine shop to partner with. Thanks to ...
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