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Greta
01-22-2007, 04:43 AM
This thread is for the discussion and progress reports on current outstanding projects of andrewwynn (AWR). I have closed the following threads:

AWR nano round one/the final chapter/Part2 (http://www.candlepowerforums.com/vb/showthread.php?t=141924)

AWR 'Hotdriver' hotwire LDO driver for Mag/Part2 (http://www.candlepowerforums.com/vb/showthread.php?t=141925)

AWR Hotdriver-M6 Regulated SuperLDO FS-Part 2 (http://www.candlepowerforums.com/vb/showthread.php?t=141873)

This thread is for the sole purpose of updates and progress reports regarding these projects. This will be the ONLY thread allowed on CPF for that purpose. A single seperate thread has been established HERE (http://www.candlepowerforums.com/vb/showthread.php?t=149796) in the Jeers forum for any other discussions regarding these projects. IOW, only posts from AWR himself and questions regarding the progress of these projects will be allowed in this thread. Any other comments... go to the Jeers forum.

Macaw
01-22-2007, 09:37 AM
Andrew: How is the Nano project coming along?

greg_in_canada
01-22-2007, 09:51 AM
More specifically, did the 22 finished nanos (that were waiting for chargers) shown in your photo get mailed out?

What is the status of the remaining nanos?

Thanks - Greg



Andrew: How is the Nano project coming along?

mudman cj
01-22-2007, 10:26 AM
I was told my HD would be shipped a week ago...can you please update the expected shipping date?

andrewwynn
01-22-2007, 10:36 AM
NANO:

The parts came in for the chargers, but the prep was only recently completed.. my part time help dropped from 4x/week to an average of 1x/week since the christmas season, but has recently picked up. any day could be the windfall start of 'bunches and bunches'. To complicate things once more.. the wrong bodies were sent from peak for the light bodies, requiring some additional re-engineering.. i've been hammered by posting updates so i stopped, cpf has become completely awr-unfriendly, something that can't be remedied 'til the nanos and hdm6 are shipped, which is completely understandable, but the amazing amount of discouragement to encouragement ratio has added months to people's waits... This consolidation will likely help things, especially if folks can stop with the relentless awr-bashing that doesn't help anything or anybody... i'm plannng as posted back in november to have all hdm6 and nanos done by february as in .. before march..

Nano's have been partly on-hold because of fine-tuning for reliability and mostly because the charger heads and bodies needed a little bit of prepwork and the 'preppers' have not been available to work.

I'm not setting any deadlines for when to expect the first groups to come out 'cause it never happens.. other than to say, there will be 'significant motion' in all three departments.. HDM6, nano and hotdriver (which never really had and serious problems... the average delivery time on hotdriver is about 3 weeks).. There have been some cases of lost in shipping or lost in the shuffle where a hotdriver order was way out of the norm.. the avg. is still 3 weeks.

By mid. march i expect to have everything caught up and parts on-hand for immediate repairs of any nanos and immediate shipping of any model hotdriver.

Negative posting at this point (and since it's started) has done nothing but slow progress more.... imagine trying to get work done and having a constant barrage of such... your production level is going to drop precipitously no matter what your job is.

HDM6: The first batch of drivers was completed mid-november.. there was a problem with the production of the rods that hold the pack together so the first batch of the bat. packs were held up through december and 'til now while an invention was made to solve that problem. I am waiting on a simple 2 1/2mm tap to finish that fabricator and that was ordered last week and due any day.. the first batch of a dozen or so HDM6 will be fabricated immediately following the arrival of that tap that's holding up the progress.. basically it amounts to putting the threading on the rod... the first samples using the un-insulated rods went very smoothly but threading the insulated copper rods turned out to be an everloving PITA.. they came out looking like wiggly worms and took forever... that problem was worked on from a different angle and should soon be resolved.. i didn't finish the thread-maker and was waiting 'til i get the tap before i would show the results.. posting w/o a picture of progress has gotten me nowhere but deeper in a hole so i just didn't bother.

Hotdriver: there are a few 'in the shop' and just a couple that have been ordered and not made yet... if you have been waiting more than 4 weeks you'd better send me an email.. if you don't get a reply within a day it means i didn't get your email so use the hyperlink at the bottom of my post to use the cpf emailer.. their outgoing server is in the whitelist to avoid spamination.

I will post timely updates here, please keep questions 'pertinent' and i will reply to every question as 'pre november' i have always done.

-awr

andrewwynn
01-22-2007, 10:39 AM
mud... i think the 4x down to 1x/week got your shipping pushed back, but today is a normal day to expect motion for hotdrivers so i will check into what happened with your driver not getting out or if it was sent and lost or such (we had 5 or 6 hotdrivers shipped in december 'go missing' in the hands of the usps)... they were replaced with new ones... part of the hotdriver delay of late.

-awr

mudman cj
01-22-2007, 10:44 AM
Yes, I know of the lost shipments because mine was one of them (although mine was before December). Please remember that I paid extra to have this one shipped with insurance to prevent that from occuring again.

andrewwynn
01-22-2007, 11:06 AM
after loosing over $500 in hotdrivers in december.. trust me.. insurance is the game-plan from this point out.. the problem with usps is that the items they have lost never were 'in the system' at all! like they fell off the cart on the way to the first truck.. anyhow, things are not very far behind in hotdriver land, and thanks for bringing to my attention your pickle so we can make sure you are covered and get your driver!

-awr

Josey
01-22-2007, 11:21 AM
My Hotdriver has been paid for and on order for almost 5 months. Still waiting delivery. I tried a polite inquiry by email quite a while ago, but got no meaningful response.

andrewwynn
01-22-2007, 11:28 AM
I don't remember the email coming in, I certainly would have replied to that! From memory i think that you have a '623 model that kept self-destructing and sadly just kept getting bumped to the bottom of the pile after that happened.. the last email i have from you is from november and you are in the 'whitelist' if you use the 'starband' email.. i will send you an email and also if you have a use for it i'll make you an add'l hotdriver to make up for the longest wait of anybody to get their driver! post or send an email and i will definitely figure out some helpful compensation for your wait.

-awr

andrewwynn
01-23-2007, 06:40 PM
lots of progress today on nanos.. the rest of the charger heads were prepped.. the charger bodies most were prepped and the light bodies were 1/2 prepped (they still need the o-ring and the pro-gold).

hdm6 are still waiting for the threading tap but i got a tracking number yesterday finally .. took about a week from order to shipping.

hotdrivers.. major catch-up and tracking down the loose ends.. if you ordered more than a month ago and haven't already been in-touch with me send me an email so we can make sure yours is finished asap... there are a handful of drivers already made (since nov) just needing testing and assembly into KIUs, so we should be 100% caught up with all hotdrivers by tues or wed of next week.

Argent60
01-26-2007, 04:55 AM
argent.. actually i will have it apart tonight to figure out what is wrong and it should be running by tomorrow, you can expect a repaired or replaced unit on the way by tuesday and usps will send a shipping confirmation.

AWR-
It's now three days past Tuesday, and no word yet. Has my Hotdriver been sent? :popcorn:


Argent60

cdosrun
01-26-2007, 11:05 AM
AWR - Just a quick question. I ordered a hot driver one month ago knowing that would take a while, so I am not shouting and screaming; any idea about when it will be sent?

thank you,

Andrew

Argent60
01-29-2007, 04:00 AM
AWR-
It's now three days past Tuesday, and no word yet. Has my Hotdriver been sent? :popcorn:


Argent60

It's now 6 days past Tuesday. Andrew, are you out there?

Tritium
01-29-2007, 06:02 AM
Well I took it on myself to FIX my DOA Hotdriver last night. Success. The wire to the negative connection was not soldered down (not a cold joint just not soldered down at all to the mag switch assembly).


Thurmond

cnjl3
01-29-2007, 07:09 PM
Well I took it on myself to FIX my DOA Hotdriver last night. Success. The wire to the negative connection was not soldered down (not a cold joint just not soldered down at all to the mag switch assembly).
Thurmond

So....
Now that you have the '3rd' VersionTwo HD working...
What bulb are you using?
http://www.candlepowerforums.com/vb/images/icons/popcorn.gif

Tritium
01-30-2007, 08:02 AM
So....
Now that you have the '3rd' VersionTwo HD working...
What bulb are you using?
http://www.candlepowerforums.com/vb/images/icons/popcorn.gif

64625 Osram 100 watt. It will light up about 40 acres enough to locate livestock at night. :grin2:

One of my batteries leaked in my host and I am NOT happy about that since it cost me about $120 bucks for the 4 bore host. Batteries are CBP 1650's

Thurmond

Bob_G
01-30-2007, 12:32 PM
Thurmond, have you seen SilverFox's comments on the Titanium 1800? Check at the end of his first post in the NiMH Shoot Out (http://www.candlepowerforums.com/vb/showthread.php?t=79302) thread. You should get some :)

Argent60
02-01-2007, 05:29 AM
It's now 6 days past Tuesday. Andrew, are you out there?


It's 9 days past. Still waiting.....


:popcorn: :popcorn:

andrewwynn
02-01-2007, 10:54 AM
argent... the damage to your hotdriver was indicative of a reverse-voltage applied.. it has been repaired and is boxed for shipping.. make 100% positive the voltage is Positive going to the center of the switch body where bat+ would touch if using D size cells.

HD is not tolerant of reverse voltage.. fortunately if the voltage applied is less than about 10-12V it will survive (perhaps only if no load).. but i've blown a few by accidentally hooking up voltage backwards.. so people please be careful of reverse voltage on a hotdriver. I will usually (as in this case)..

cdo.. leigh just mentioned yesterday she was working on your order, not sure if she finished and ready for shipping but it's basically one day (leigh working day) away from having it ready to go or even shipped... expect it next week.. if you are usa, you'll get a shipping notice from usps.

tritium.. i've been wondering about your case i never got the bum driver back... sorry i missed the missing solder joint.. i've caught a couple of those when a HD is reassembled after repair leigh's missed re-soldering that joint, and when i test, i just clip onto the wire so it will pass the test.. i am pretty sure i assembled the driver into my 4D host to test it, but pressure must have held it together enough for the initial test. Since that particular driver does use vBat for shut-down you will get 10% or possibly even more runtime compared with the vOne hotdriver that shuts down via vLamp. I have spare 1650s and will send you one free if you need one to re-fill your pack.. i always buy an extra because i've always had about 1 of 12 fail.. hope it didn't cause terrible damage to your host (to be clear to other readers, i didn't supply the original batteries.. just offering a perk to somebody that deserves it... tritium).

Bob-G... will those hold 10A? I just looked at the chart.. at 10A.. the only hold 1.08V/cell.. but the cbp it looks like didn't do any better.. it would be interesting to see them in use.

we are just about 100% caught up with all hotdrivers.. i have to figure out what is up with mudman, but there should be no more stragglers after this week.

nanos had a good week last week having the last of the prep done... there was a reliability concern from the first testers that went out with the 'near final' design and a small fix to that which was just made, we've been tryign to get all the hotdrivers out of the way to work tag-team on the hdm6 and nanos w/o distraction. Things are looking good to meet the done this month goal.

hdm6... the 'stick in the mud' holding things back (threaded rod fabrication) is solved... the threading die put so much torque on the rods it was turning them into cavatappi (http://en.wikipedia.org/wiki/Cavatappi). To solve this production issue i designed what i call the 'thread crusher'.. and had a guy CNC machine some jaws that go into a bolt cutter that literally crimp the threads onto the rod w/o twisting... it only forms the threads about 90% but it's so easy to thread with the die now that i can twist the die handle with a pinky finger and the rods no longer are twisted into corkscrews... it was very difficult to thread the hardened steel jaws and i broke the first tap, but now it's done so hdm6's are finally near to being chugged out.

Tritium
02-01-2007, 12:09 PM
tritium.. i've been wondering about your case i never got the bum driver back... sorry i missed the missing solder joint.. i've caught a couple of those when a HD is reassembled after repair leigh's missed re-soldering that joint, and when i test, i just clip onto the wire so it will pass the test.. i am pretty sure i assembled the driver into my 4D host to test it, but pressure must have held it together enough for the initial test. Since that particular driver does use vBat for shut-down you will get 10% or possibly even more runtime compared with the vOne hotdriver that shuts down via vLamp. I have spare 1650s and will send you one free if you need one to re-fill your pack.. i always buy an extra because i've always had about 1 of 12 fail.. hope it didn't cause terrible damage to your host (to be clear to other readers, i didn't supply the original batteries.. just offering a perk to somebody that deserves it... tritium).



Hi Andrew,

I have a few extras as well so thanks but a 1650 is not necessary.

Thurmond

andrewwynn
02-01-2007, 12:22 PM
that is good to hear.. moreso i'm glad to hear the driver is running, that's what's really important.. the 625 is one of my absolutely favorite lights, and even mine is non-operational i sold my driver to somebody and leigh has a pretty solid rule that everybody else gets theirs first.. so i myself have been 'waiting since november' for my hotdriver too (like 3 or 4 of them actually).. so i definitely 'feel your pain' anybody that's waiting.

cjmud... i didn't remember your order at the last post but just looked it up.. your driver is made, just needs assembly into the KIU and as i mentioned in our emails.. i will include fabrication of the tailcap resistor into a 'drop in' unit and test it in my 4D LION host before sending it out.

-awr

Bob_G
02-01-2007, 03:32 PM
Hi Andrew,

I was mostly thinking of the leakage/failure issues with the CBPs. The Titaniums look like they hold a little better to me, but I've never seen SilverFox test RC type cells so there's nothing to really compare at high current loads. It would be nice if he got some current 2/3A and 4/5A to test like the Elite 1500/2000 so we could see how they do with the same person testing them with the same procedures as the others.

Does the 625 pull a full 10A? I was thinking it was more like 8.5 or so, but could easily be confusing it with something else. Mine runs on 11 Elite2000 very nicely - can't wait to see what it does with a 3" head :)

andrewwynn
02-01-2007, 04:18 PM
I am completely unimpressed with *any* AA cell at loads over 6A. i don't recommend them and recommend against them... the best match for high-output and AA is the 12AA and 64610 lamp it's an amazing match up.. I have made a handful of 100W lights and with CBP 1650s i expect about a 7 minute run out of them.. those titaniums actually looked ok and might be better for the '610.

625 is 9.5A.. pulls about 30A at startup.

you will like the 3" head a lot.. i tried the 625 in a 3" head (from elephant) a while back.. took out the anomalies almost as good as a stippled reflector.

a 3D light can fit 12xAA in a quad config or it can fit 4/5A x 12 in a tri-bore config.. doesn't take rocket science to figure out which is the better solution for high-current lamps.

a 2D can be modified w/o much difficulty to fit 11 or 12x 4/5A or 16-18x 2/3A as well.. the same pack that was in my first '44 mag' prototype (16x 2/3A) now fits into my 2D prototype!

-awr

hburner
02-04-2007, 06:36 AM
OK, I have been staying away from asking questions and stuff because of all the heat that has been generated around the hotdriver, but, since I have gotten into making a few hotwires, I am instaflashing a few lamp, 2 yesterday. I am learning really quick to discharge the edge off of the cells.

I have never saw a final price for a hotdriver. How much is one? I really would need 4. AWR if you get a chane to respond to my questions would you please? All for D size hosts and what is the expected delivery time for a 4 piece order? Thanks, hb/

andrewwynn
02-05-2007, 01:55 PM
hburner.. check your email.. sent with the mail webform from cpf .. if you didn't get it, send an email using the email link in my signature. i invented the hotdriver because of instaflashing 1331 and 1185 lamps 'like popcorn'.. so i know exactly what you mean. Turnaround on hotdrivers is not terribly long.. a couple got really lost in the baffles and took forever the average is about 2-3 weeks payment to shipping.. over christmas time it got a bit longer maybe, when leigh is more scare (she does 90% of the production of hotdrivers). I will pay shipping and now i also get insurance on all hotdriver orders sent (after the post office lost about $600 worth in december!).. i need to know the exact battery and lamp combination to advise which driver you'd need.

-awr

dizzy
02-05-2007, 02:08 PM
Andrew, any news on the HD-M6 production? How are the rods turning (no pun intended) out?:)

andrewwynn
02-05-2007, 03:49 PM
the rod threading machine turned out perfect, only made the first one so far, but the difference is mind boggling, and i expect to get honkin' on them as well as a big batch of nanos this week, as i've not lost sight of the february goal.

-awr

frisco
02-05-2007, 04:03 PM
hburner.. check your email.. sent with the mail webform from cpf .. if you didn't get it, send an email using the email link in my signature. i invented the hotdriver because of instaflashing 1331 and 1185 lamps 'like popcorn'.. so i know exactly what you mean. Turnaround on hotdrivers is not terribly long.. a couple got really lost in the baffles and took forever the average is about 2-3 weeks payment to shipping.. over christmas time it got a bit longer maybe, when leigh is more scare (she does 90% of the production of hotdrivers). I will pay shipping and now i also get insurance on all hotdriver orders sent (after the post office lost about $600 worth in december!).. i need to know the exact battery and lamp combination to advise which driver you'd need.

-awr


Just a suggestion..... Due to the currant climate of your status on CPF, It may give your customers more confidence if you request payment upon completion. Than there is no complaining of hard earned funds in limbo and it will give you more motivation to finish things you start.

frisco

andrewwynn
02-05-2007, 04:25 PM
that's not a terrible idea. we are working toward a completely post-pay scenario.. anybody wanting to order up a hotdriver... just email me what you'd like and we'll make it first and bill you when its ready to ship. I have enough parts on hand to do that for the moment.

-awr

Argent60
02-07-2007, 08:30 AM
argent... the damage to your hotdriver was indicative of a reverse-voltage applied.. it has been repaired and is boxed for shipping.. make 100% positive the voltage is Positive going to the center of the switch body where bat+ would touch if using D size cells.




I've done several M@glite mods like this light(except of course for using a HotDriver), so I'm sure I put the FM adapter in correctly. Have you fixed the problem, and is it on it's way back to me?

Argent60

andrewwynn
02-07-2007, 03:17 PM
driver was fixed, i just printed the label for shipping.. don't fret about the backward voltage thing... it could have easily been a defective part from the factory... just how i worded the original post.. 'indicative'.. as in the only way i've personally damaged that part was from reverse voltage, so i wanted to warn you make sure your bat pack is outputting the polarity you are thinking it is before putting it in if you have a meter.. just to be 100% sure..

Sorry your driver repair got behind so many other things.. i greatly prefer it is where it belongs.. in your hotwire light than on a shelf waiting for repair.

-awr

andrewwynn
02-07-2007, 03:44 PM
double post.

dizzy
02-08-2007, 02:01 PM
Andrew, do you now have all the cells to complete the 3300mah and the 4800mah battery packs? I don't remember hearing that you received the new cells from AW. Also, did you ever find out what happened to nuggett's 4800HDM6?

For those that have had the 3300mah HDM6's for a while now, any updates for us? Hopefully, no news is Good news.:)

WAVE_PARTICLE
02-08-2007, 02:13 PM
RE: HDM6 packs

Andrew, are we still on target for "before March" delivery?



WP

andrewwynn
02-09-2007, 11:52 PM
yes on the no news is good news. i'm not making predictions but to ans. WP.. yes, the last major hangup was the rod threading... threading the first tester brass rods went perfectly and though the copper was giving me some fits, i was able to make several, but it took forever.. the news system works great and finally a feeling of 'production line' came to light.

update on nugget's 4800 will be online soon.

-awr

cue003
02-10-2007, 06:17 AM
looking forward to getting these. andrew as we discussed via email. my order should be updated to the smaller original size pack since I sold my XTN.

Thanks.

Curtis

dizzy
02-10-2007, 06:32 AM
Andrew, do you now have all the cells to complete the 3300mah and the 4800mah battery packs? I don't remember hearing that you received the new cells from AW.

What about the cells? Do you have them?

andrewwynn
02-11-2007, 12:30 AM
diz.. got the cells for the first 2 batches.. that's about 1/2 and the next order lined up with AW he's ready to ship them and ships very fast.. with having to replace so many aaa LIONs i wait 'til closer to assembly to order them but with the first 2 sets about to be assembled for hdm6, the order for the rest of the cells will coincide with that to get the rest of them made asap since feb end is coming soon.

cue: we'll send out an email just before shipping to make sure we got your order updated correctly.. you will be very happy i think with the 3300 vs 4800 pack, though the 4800 is quite neat to see in action.

apparently there was a less than knowledgeable post somewhere else regarding the thread crusher solution to make the hdm6s... to clear up any misunderstandings about why the need for the new tool:

http://homepage.mac.com/rouses/smartpak/hdm6rod3.jpg

The top rod was made 'the old way'...

1) strip the enamel insulation off where the threads would be
2) taper the end with a dremel so the threading die would 'bite'.
3) put the rod in a vice
4) turn the threading die on the rod..

As you can see the torque required was more than the copper rod can deal with and it would twist and distort greatly, and it would also take a ludicrous toll on time and the fingers doing the twisting.. it took 10 days for the blisters to heal!

The 'new way' shown with the bottom rod:

1) crush the threads on with the new tool.. w/o stripping the enamel
2) lock the rod into a drill vs a vice to hold it
3) twist the threading die which now starts w/o tapering the end with one finger.
4) un-twist by spinning the drill.

The new way other than making perfect threads w/o twisting the rod at all.. takes about 2-3 minutes vs 10-15 minutes per rod.

The difference can really be seen in this photo:

http://homepage.mac.com/rouses/smartpak/hdm6rod2.jpg

Although the bottom two seem pretty straight.. the 3rd rod has about a 90 degree twist on one side and a 180 degree twist on the other side.

The price of innovation (the first and only battery pack i'm aware of that uses insulated rods between the batteries) was the steep learning curve on making those threaded rods. I have a couple assembled packs ready to box and a whole bunch on deck.. there have been a couple improvements based on the tester packs that went out that will improve reliability.

ps.. the 'bend' in the bottom rod is just barrel distortion from taking the macro shot so close-up.

-awr

Frank_Zuccarini
02-11-2007, 04:24 AM
Cool photos. Thanks for the explaination, and for bringing us up to date.

I am very excited about receiving my HD-M6.

Regards...............Frank

PEU
02-11-2007, 04:51 AM
As you can see the torque required was more than the copper rod can deal with and it would twist and distort greatly, and it would also take a ludicrous toll on time and the fingers doing the twisting.. it took 10 days for the blisters to heal!

You were using a threading die without a holder? that explains why it takes so long, a task like that could not last more than 1 minute per threaded side...

You need this Andrew:

http://img100.imageshack.us/img100/4115/dieholder001ag5.jpg

And of course, use threading lube, in fact almost any spray lube will help you.


Pablo

will
02-11-2007, 06:11 AM
I do not know all the specifics of these rods and why they are made of copper. I do know a bit about machining and electrical work. Copper is used in wiring because it is flexible and at a given diameter has a lower resistance than other metals. For example 12 guage wire can carry 20 amps at 110 volts and is .081 thick. This diameter is slightly thinner than a 4-40 (SAE) thread would be. I would think that a rod made from either brass, steel, or even aluminum would be a better choice. If the rod is meant to carry electrical current, then brass would be better than aluminum - aluminum oxide is not a good conductor. Copper is usually used for soft washers, ( the ability to crush and form a seal between harder metals - the brake systems on cars use copper washers ) Also copper will stretch and I believe the threads will be very weak.

You sometimes see copper coated rods, but not rods made from copper.

UncleFester
02-11-2007, 07:47 AM
Hmm....... I wonder if the rods could have been made from brass stock and then insulated with ummm.... let's say heat shrink tubing. Wow, an insulated rod made from a material harder than electrical copper. Yes there might be a little less conductivity.

will
02-11-2007, 09:06 AM
Hmm....... I wonder if the rods could have been made from brass stock and then insulated with ummm.... let's say heat shrink tubing. Wow, an insulated rod made from a material harder than electrical copper. Yes there might be a little less conductivity.

unless the rod is carrying more than 20 amps - almost any other material will work. I have to say - I don't know the size of the copper rod, and how much current it is going to carry. I use shrink tubing for lots of stuff - inexpensive - comes in colors,

threading a small diameter copper rod is like - well - trying to push a chain....

andrewwynn
02-11-2007, 10:28 AM
pablo.. using a holder made the twisting problem worse initially.. originally using brass and 'sleeving' was the plan but there is not enough room between 3x17mm cells to fit any type of insulation.. the thinnest 'spaghetti' tubing i could find or the thinnest pvc shrink wrap is about .008 wall thickness and that was way too big to still get cells to touch... the 'holy grail' of having things line up and was supposed to be 'easy peasy' was enamel wire.. 'magnet wire' because it has insulation already on it, and comes in a roll so length is a non-issue.. I had already made numerous bat packs where i had threaded copper rods with no difficultly at all.. the difference was dropping from 8ga size down to 11ga size made it impossible to thread directly..

It took months of experiments to find a combination of which threading and which wire gauge that would actually work.. and it turned out that 'if you have the patience' you can get a perfect thread onto 11ga copper wire with a 2.5mm threading die... when i did the first tests for fit and 'pull out strength'... i had only threaded about 6mm onto the rod and though it was 'tough going' to get the threads, it wasn't enough torque to cause the 'corkscrew' effect that ended up happening when threading the longer threads.

The rod only carries current about 5-8mm so conductivity is a moot point. The fact that *every single* modamag style holder i've ever seen come through my lab has had cell to cell shorting and so though the first testers which were made with brass were much easier to thread there was no way i would produce a pack without insulated rods.. i have used 3-48 rods to modify the 17mm holders from fivemega.. which don't have the shorting issue because of the plastic holders that keep the cells separated, but the rods are so thin, and very hard to find, and as mentioned.. shrink-wrapping them was not 'getting solved'... so the solution ended up being enamel magnet wire.. with the annoying but now quite completely solved hiccup of how to 'push a chain' (thanks will).. problem how to thread it.. There will be some hdm6 shipping this week and more next week.. should be a very consistent flow out the door..

Fortunately water under the bridge... and i'm far happier with re-making the first batch of rods to have them 'done right'. I was not happy after the first batch came out soo for lack of a better word 'crappy' and i needed to have them done right, now they will be.

-awr

Zigzago
02-11-2007, 01:02 PM
You are still working on the Nanos, right?

andrewwynn
02-11-2007, 06:53 PM
yes sorry i didn't post an update.. there is a problem with ground path reliability, i'm pretty sure it's solved so things will be moving again, i hope to have a very happy update on nanos in the next few days now that i finally got that resolved. the new heatsink pill was not playing nice with the contact ring on the driver board for the ground.

-awr

Zigzago
02-15-2007, 10:38 AM
I'm ready for my very happy update.

Fusion
02-16-2007, 11:02 AM
I'm ready for a happy ending....

ZeissOEM2
02-16-2007, 11:24 AM
I have been given it up waiting for Nano-spot #166 and asked for trade in a HP HotDriver.The nano was the reason that I found cpf,but it seems not to be finish at all.