Box full of bodies...

...what were you expecting?

Getting There!

Doing some finish machining on bodies today. In the photo, I've just finished grooving a stone washed shorty body. I have to do about 80 bodies total in this run. Wish me luck!

How it's made

I had a few people ask about seeing more of the process, so I thought I'd post some random photos from time to time. I also had someone ask what the "chips" were that I referred to in my last post. Chips are what machinist's call the little bits that get shaved off by the actual machining. While sawing isn't really machining (or is it?) the shot below is the best "chip shot" that I had on hand. This is after cutting off a batch of raw stock to length. That's a lot of chips in case you were wondering.

The deck of my chop saw..the lip on the pan is about 2" deep. 

 After all of the parts get cut to length they get piled into boxes and it's on to the next step. The saw cut edges are quite sharp and have "burrs" on them. I need to debur one end before it goes into the CNC mill so the parts sit nice and square. Otherwise, the burrs would make them tip one way or the other.

Cutting the stock to length is not my favorite job. Earplugs and annoyed neighbors required

NEW PRODUCT FOR SALE: Titanium Zipper Pulls !!!

Hey Folks,

Looking for an awesome gift? Want to personalize a mass produced jacket or bag? Want to win friends and influence people? Try some of my pure titanium zipper pulls!

It's been a long time coming but I pulled the trigger on a batch of these! They are machined at Hirsch Machine in Santa Clara, the same place that makes my Ready Made lights. Check out this link to purchase them directly from my site. There are lots of photos of pulls on things like jackets, sweaters, bags, and flashlights so check out the link. If you buy some pulls, please send me a photo of the item you personalized and I'll post it on my site!

I had to take a hefty bite out of my checking account to make this happen so please help me spread the word! Blog, tweet, share to Facebook, email the gear-head in your life, anything you can think of! Your help is greatly appreciated.

These are also available for wholesale, so if you are a retailer, please contact me!

Prometheus "Writes": Montblanc style

Okay, so I haven't been posting much because I've been busy coming up with more awesome. I've been wanting to do this project for years but just never got around to it. I've you've never used a Montblanc, it's writing nirvana. I mean the cartridge, not the pens themselves. Considering a Montblanc starts at about $350 and goes to well over a grand, most people have never used one. I bought a good friend a Montblanc when they graduated from law school and I took it for a test drive before handing it over. I was astonished and I've used nearly every pen on earth.

The Mont-Alpha ? 

The prototype in the photo is armed with the Montblanc "FineLiner" which refers not to a cosmetic product, but to a fiber-tip ink cartridge. It's kind of like a felt tip, but it's firm and doesn't wear down and get fat like felt pens. However, you can control the line weight like with a fountain pen, and it writes just as smooth and dries immediately. For you traditionalists they also make a liquid-ink ball point cartridge that is interchangeable. The FineLiner comes in blue and black, while the RollerBall comes in a host of colors.

A brass button head screw

This prototype is raw, un-plated aluminum with a "machined" finish. This is how it looks right off the lathe, no sanding or polishing or anything like that. I plan to offer a nickel plated (to match my lights) and (drum roll) a titanium version as well!

The cap screws on and uses the titanium clip that I make for the Peak Eiger flashlight, with a slightly shorter bend at the shoulder. Blue fluorosilicone o-rings provide a nice grip surface. Soft but positive. Since the photo was taken I've added a 5th ring closer to the tip of the pen. The "styling" is up in the air and just what ended up with after a frenzy of machining. The production version may (or may not) look similar. Whatever the case, it will be a full-size pen with a screw cap and accept either the Montblanc FineLiner or RollerBall refill. The refills cost about $7-$8 each.

Any interest? :)

Joby, meet Alpha. Alpha, meet Joby.

I've been fooling around with some "other' ideas about what you can do with a light. One drawback to flashlights is that you have to hold them in your hands. Joby even makes their own line of lights that mount to their tripods...but they are...wimpy. I wanted power, anywhere, anytime. So, I headed over to the CNC mill and made myself a set of three mounts. These are prototypes so I just hacked them out in an afternoon.

The cool thing about this particular tripod is the little red feet are magnetic, increasing the versatility even more. It's amazing for automotive work.

Time to start putting light where I need it

Most people think headlamps are the solution to hands free personal lighting, but I think for the most part, they suck. Don't get me wrong, I have 4 headlamps and they have their purpose...last resort lighting. My most frequent use is a tiny Black Diamond light that I wear around my neck when I'm in camp. Oh but you need to "work on something" and have your hands free right. Ever notice how having the light close to your line of sight is guaranteed to make your hands cast shadows on your work-space instead of actually lighting it?

Zipper Pulls V2 (Titanium boyyyyyye)

Okay so I was feeling a little frisky in the shop the other day. I ordered a 12" chunk of commercially pure titanium and decided to turn the whole thing into a bunch of zipper pulls. All of this was done on my Hardinge HLV-H manual lathe. No fancy computer stuff here, just old school handle crankin'.

Clean as...well, you come up with something

My friend Wilson looked at my first prototype and suggested I come up with some way to hide the knot. After some reflection I decided that was (1) a good idea and (2) perhaps even possible. This is what I came up with. The bottom of the pull has to be flat, instead of rounded, but I'm happy with the well balanced result.

So dear public, is this something you'd be interested in owning? Let's not talk about price yet...but keep in mind titanium is ridiculously expensive. I think these are awesome for adding a little custom touch to any mass produced garment, messenger bag, flashlight, pocket knife, camera bag, key chain, whatevs. I also think they would make awesome gifts that are unusual and classy (remember, it's titanium). Dear public, what say you?

Read on after the jump for more photos and explanation!

My latest creation!

Hi folks,

Hope everyone had a good Christmas! I was trying to figure out what to get my Dad this year and then it became pretty obvious that it should be a bespoke light...but what kind of light? I had some roughed out spares for my limited edition copper batch so I pulled a set and stared at it for a couple of hours. A couple more hours of manual machining and viola! Looks easy right?

Thus far...my favorite light!

"Bamboo" is my inspiration for this design and I think it actually came out quite well. I liked the idea of using a "natural" form and applying it to metal with machine tools. Conceptual contrast as we call it in the industry. The finish is completely as-machined. No polishing at all. It was next to impossible keeping the finish pristine while making it and then flying it half way around the world but it worked out.

Just since Christmas the light is already starting to develop it's patina just from handling the light. The oils from your skin (and any other contact) causes the copper to stain and oxidize. Eventually the entire light will become a deep brown/green and only have highlights on the high spots where it gets handled the most.

Solid Copper: one-of-a-kind custom

Hi folks. Sorry about the lack of content. I've been super busy and slightly de-motivated on the blog front. I've been working hard though! Just wanted to share a one-off custom light I did for a chap in the UK. He's been very patient with me and this is the result. Hope he likes it as this will be the first glimpse of his new light that won't go in the mail till tomorrow :)

I have a batch of limited edition copper lights currently for sale. I had a fellow contact me about doing some special work on his light, and this custom was born.

This thing is a tank. I hope my customer has a stout belt. 

This is also my first light to feature tritium vials. Tritium is a mildly radioactive element that glows on it's own. No need to "charge" it like normal glow in the dark materials. It's half-life is about 10 years. Don't worry, the radiation is so weak that it can't escape the glass vial...and if it did, the amount is so tiny it wouldn't hurt you anyway. Read on after the jump for some photos!

Variations on a theme

I've been playing around with some variations...partly to evolve the design, and partly experimenting with better thermal management. Several people have mentioned they would like something more complex and ornate. So, I'm starting to work with some different options. Of course more machining take more time...and costs more money. I can afford to add some complexity but not a lot.

Click for a larger view

At this stage I'm just trying things out...prototyping as we call it in the industry. A lot of people would sit down and "design" something on paper. In this case, I'm using aluminum as my "paper" because I tend to think better in three dimensions. I'd love any feedback or suggestions. Have an idea that you want to see me try out? Let me know and I'll do my best to make it happen!

Odd Job: Mission Motors

Hi folks, thought I would do a bit of a random post today. Before I started flashlights a few months ago I was doing custom fabrication work out of my shop. Mostly one-off things and mixed fabrication/project management. Say you need something designed, machined, welded, coated, and delivered yesterday...it's hard to find one shop that can do all of that...so people come to me. I used to work for Mission Motors up in SF, and I still do the odd job for them from time to time.

parts and prints, always satisfying! 

A couple weeks ago they needed some bits for their race bike so I spent a couple days getting these together. This job was straight forward CNC and manual machining from their prints so it went pretty quick. The last big job I did for them was a set of display stands for SEMA. Read on after the jump to see the bike and the parts I made!