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? :)

Prototype Titanium Tailcap Button

Hey all, this is one of those accessories I've been planning to do from the beginning but never have the time to work on. It looks pretty simple but this is my 4th prototype. The button is designed to be a direct replacement in all Alpha's manufactured to date.

Stay classy my friend

Right now I'm still trying to find a return spring with the right force. The button has an o-ring around it which needs to fit tight enough to keep out water, but a spring is needed to push the button back into the "out" position. The tighter the seal the firmer the spring needs to be and the harder the button gets to push. It's been a little tricky to balance...BUT IT LOOKS AWESOME!

Ce n' est pas une zipper pull

Recently someone asked me why the heck you'd need a titanium zipper pull when all zippers already come with pulls attached?

My first answer...you don't need them, you want them...just follow the swinging pocket watch with your eyes. Second answer: rather than a 9,000 word treatise on zipper pulls I decided to post the following 9 photos.

Let's begin with # 1 shall we?

Does this really need a caption? 

More photos after the jump. Don't worry, you won't even have to read "much" more text or look at my grungy Carhart jacket again :)  

McClicky Switch Mod Part 2

Well, I don't think anyone was sufficiently impressed for my liking, so I decided to step it up a notch. I completely disassembled the switch and gold plated all of the internal metal components...even the ones you can't see in the photo :) I bought myself a little gold plating setup a few weeks ago and this was my test run. I also plated the (already nickel plated) retaining ring just to show off :)

24K gold, need I say more ? 

WIN: I modded the world's best flashlight switch

I should say right up front this is going to get pretty geeky. Like comparing two different types of springs geeky. Better buckle up. I was at a manufacturing trade show (better latch that tray table as well) and found a company called Smalley Steel Ring Co. They make some really interesting stuff...enter the wave spring. It's time to loose the conical battery contact spring and get with the wave spring. I'll be integrating these into my lights as soon as possible.

No flashlight should use anything else. So, when everyone starts doing this, you heard it here first :) This is henceforth known as the "Prometheus Spring!" Cue the music...or you can just check out my first prototype integration after the jump.

They even look cool right? Besides that, there are even more advantages over a standard conical spring. Here are the highlights:

1. No sharp edges. A typical conical spring is really sharp where the last coil is cut off and that cuts into the thin metal on each end of the battery. Long term...not good. It also makes the light feel awful and "scratchy" when opening and closing. Right now I have to put a blob of solder on the PCB spring and the McClicky switch spring to prevent them from destroying the batteries.  
2. Distributed contact area: Each wave spring will contact the battery at the crest of each wave...typically 4 different places. A conical (or coil) spring only has one point of contact. Multiple contact points distribute the load generated when the light suffers shock...for example, when dropped. Every effort should be made to protect li-ion batteries from physical damage. 
3. Shorter current path. In a typical spring the current must pass along the entire length of the spring, as if it were a straight wire. More distance equals more resistance, and resistance is bad. As you can see in the photo above, each crest touches a trough, making the current path incredibly short.

If you made it this far you might as well read on after the jump. More photos! You like photos right?

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!

Side Projects: Zipper (awesome) Pulls

I don't really have time to be doing side projects...but I've been thinking about this one for ages. I had a little down time yesterday and decided to whip out a zipper pull. When I started, a tear drop shape was the plan, but ultimately I was really happy with this "pill" shape. I'd actually like to make an sell these, so please leave a comment if you'd be interested. I'm thinking I'll do them in both nickel plated aluminum (to match your Alpha) as well as titanium.

A 6061 aluminum zipper pull with 2mm spectra cord