Frame/heat sink to hold 6 LEDs. Opening angle is 11 degrees to fit inside rudder. LED holes set at 20 degree angle. Weighs 90 grams.

Luxeon 5 watt white lambertian emitter LED

Back side. Metal heat sink slug must be thermally connected to frame but electrically isolated.

LEDs bonded in with Emerson and Cuming Stycast 2850 FT and catalyst 23LV. Stycast is epoxy with ground alumina added. Grit prevents electrical contact. Stycst with the LV catalyst is very runny so I added some cabosil to thicken the mix.

Through the microscope

Wired with teflon wire, Voltrex heat shrink. Heat shrink is bonded in with gel superglue. Lens is Lexan, 1 mm thick.

Current is 1/2 amp, this is NAV mode. Will stobe 6 amps using a circuit made of a 4555 and a Vfet.

Here I have added a 1 mm thick aluminum access panel/heat sink. I will cut this down to less than half this size since the lights run quite cool.

attachement ear added, circuit installed.

complete unit.

Close-up of the circuit. Active components are LM555 and IRF 2804.

These are the five 20 W 5.1 ohm resistors in TO 220 packages.

tail strobe schematic