very nice unit, i would be carefull of the heat from the heat sink, its difficult to tell from the design where the heat sink heat is lost, these things run very hot, as you have them wired like i do then you may be only supplying them with 800 mA, the driver can supply 1 at 1000mA but then as more are connected in series the power supplied drops slightly, if you could find something like a 1.2Amp driver then you would up the power, i have not yet looked for one.
the 1000 mA Konlux was thier highest rated controller iirc when I bought the parts 15 months ago. they do all the way upto 2800mA for P7 now. You're right about the heat sink, it was to hot to handle when testing outside the case. Was thinking it was going to need vents but doesn't seem too bad in the case. The wiring could be shorter but I'm not much of a solderer. But it was in then end much easier than I thought it would be.
Having a heat sink inside the case is pretty pointless really, it's all about getting the heat from the LEDs to the outside of the light as efficiently as possible. If the outside of the light's not getting warm, then the heat isn't being transmitted outwards and it'll be getting very hot inside. Eventually your LEDs will cook and lose efficiency and you could, as Serge says, fry your circuitry...
I've just killed a bflex on an early build because - I think - it simpy got too hot inside on full whack due to inefficient heat sinking of the LEDs there's no visible damage to the driver, but despite the LEDs being fine and all the wiring giving continuity, the light's dead. Generally as long as you're moving, the flow of air clears heat pretty effectively, but you need to watch it if you stop for longer than a minute or so.
with my lights i have effectivly used the whole thing as a heat sink, i assume you have used your hair gel tin to mount the heat sink and the konlux unit, try and get some of that metal to the outside of the inner tube, that may get hot and so is transfering the heat. to give you some idea i ran a single led at 1 amp for a few minutes without heat sink, it melted the table under the star.
yep, definately concerned over heat build up. Had the unit running for an hour on the desk, seemed to be no ill effects though the case was quite warm. There was no signs of melting inside just a fragrant smell of hair gel . Hope and Lupine have gone for large surface area cases/case heat sink designs, I guess only time will tell with my efforts.