In this instructable you can see how to make a super powerful flashlight
The flashlight has a 100w led that can produce 10000 lumens
I used a huge lens recovered from a krokus photo enlarger
Step 1: Installing Led and Lenses
For the flashlight I used two lenses, one made for this led and the one i recovered from the photo enlarger.
First install the lens inside the pvc pipe, mine was a perfect fit
Make holes in the cooler body, add thermal paste and attach the LED with screws.
Add 2 x L shape brackets to hold the small led lens and also use them to attach the assembly to the flashlight body
Experiment for the best distance between the lenses, and then drill the holes for the brackets in the flashlight body.
Step 2: Flashlight Body
Cut the pvc pipe for the flashlight body
Use a milling cutter to make the adjustment system.
Cut a hole in the rear cap for the second cooling fan and attach it with screws.
Make holes under the flashlight for cooling
Cut holes for the on/off buttons, fuse, voltampermeter and temperature meter
Step 3: Wiring
I made a rudimentary electric schematic and I hope it will help you.
I used a 12000 mah li-ion battery pack to power the led
I made the battery pack with cells recovered from cordless drill battery
The battery pack has 12v, the led works at 33v and 3amp max
I used 250w dc-dc booster to make constant current and constant voltage for the led
I added a voltampermeter for the booster and Lipo Battery Voltage Indicator Tester with low voltage Buzzer Alarm for the battery pack
At the end you can see some pictures with the flashlight vs darkness.