Evil eyes – a CAD rendering of a twin P60 drop-in lamp

Using a milling machine with a 4, 6, 16, 24 and a 26,5 mm mill this design is a possibility.

It is made from two pieces of aluminium each 60 by 35 mm, two P60 drop-ins from Kaidomain, lenses and o-rings from Dealextreme and a 12 mm switch. The XM-L LEDs on 20 mm stars are mounted directly on the finned rear section, thus giving the best heat transfer possible. The main body could be finned also.

O-rings between housing and lenses provide sealing at the front. Between the two parts of the housing I’ll use liquid gasket.

Below is an animated assembly.

Lamp-explode

The drop-ins are $9,21 a piece including LED and LDO regulator. The lenses and o-rings are less than $1. Get your hands on some scrap aluminium, and you’re looking at a pretty cheap 1800 lumen lamp. For added power – just scale this thing to have more drop-ins….

Have fun!