MR11 HID conversion to LED

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If the driver is the problem, I can machine the cured epoxy & board out of the pocket in my lathe. If it's the LED then just have to desolder it, remove the 2 screws , & resolder new star in place.
 
I received a sample 50-2366FR thermally conductive polyurethane potting compound.
I hope to get it ready in the next couple of weeks. pdf file below..
 

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Sorry for not updating this thread. Unfortunately my weekends have been busy in Brockville, getting my brother-in-law's house ready for sale. He's 76 & moving into a retirement home.
 
Finally got around to potting the driver into the heat sink last weekend.
I will post an update & photos this week.
 
Finished the driver , lamp & cannister assembly. The cannister is a little big, it was designed for 10x NIMH c cells.But a little foam mat cut & placed worked nicely. The beam on the dry wall is at 10 feet, the screws are at 24" centers.
Nice benefit of using clear polycarbonate for the lid, I can see the batter pack LED is on or off.
 

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Here is the beam image from 10 feet on drywall in my basement
 

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I took the light on a wreck dive in St Lawrence River, 3rd week of July.
This was my first dive with the LED head & I am pleased with the output.
It was also a shakedown dive with my sidemount rig & my viking drysuit.
The canister was butt mounted, not on my belt (where I used have it: backmount diving).
I managed to bang it on a rock taking off my Nomad, & it cracked the clear polycarbonate cover at the toggle switch.
This is the weakest point, since it is recessed for the switch (on the inside).
So looks like I need to machine a new cover, I'm also looking for a switch with longer threaded mount so I can have more material thickness at the switch location.
The alternative is to change to ABS, or Delrin (not transparent) which are less notch sensitive, & less likely to crack during abuse.
 
I'm happy to report my DIY Light Head & Canister are still running well.
The crack hasn't gotten any worse, but I've only had it on shallow (60 ft or less dives)
 
https://www.shearwater.com/products/teric/

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