Lot of hand work going into this one - looks great!
Nice collection off parts your got there. I take my hat off to you guys and your designs.
Flasklite? Please tell me that light comes out one end and booze comes out the other. :bigsmile: Im looking forward to your build.
I appreciate everybody’s encouragement, looks like I’ll need it. The homemade copper threaded end cap build has proved very challenging. Dry fitting is great, everything is all springy and forgiving, but when locked in with solder, it’s got to be perfect, or no go. Going to sleep on it, tomorrows a new day.
Well, flasklite because the end product will look like a flask? Instead of two 18650’s you could use only one, then you would a free tube for some Schnapp’s …
Looks cool. Have you tried sanding to loosen it up? Or some silicon grease?
Foy fully approves of the name "Flasklite."
absolutelyawesomeFoy
More severe than that, I tried a triangle file to clean things up! Mostly it will come to making a jig of some sort that puts the female coil in square and keeps the pitch spacing. If I can find some 3/4” dowel stick laying around, that will be a good start. Then I could solder with it in place, till the coil is tacked in.
Attempts up till now have been fairly close tolerance, need to loosen it up a good bit.
Looking forward to seeing more!
You know how I love using a drill. How about chucking the part into the drill and turning it at low rpm with the triangle file? Might give a better feel for the pitch of the threads.
Added some pics of the P60 build.
RBD I built a thread pitch maintainer tool for female threads, and this worked pretty good while doing the soldering. You can see it in the added pic next to the P60 mod.
Took a bit of a break on the threads, and started in on the P60 mod necessary to fit the zoom function. I am giving up some flood by retaining part of the reflector so I can use the factory relief/kerf for an o-ring. Expanded the kerf with triangle file to fit a 7/8” o-ring. If too much flood is lost, or unsightly artifacts introduced, I will revisit my thinking on this. Also soldered a 14 ga. wire ring to the driver pill, to shoulder another o-ring. This all fits and functions nicely in a 3/4” coupling, and operates very smoothly with a little lube.
Bad news, I chipped my acrylic aspheric lens, trying to horse it into my failed lens cover attempt, (note to self, don’t do that). Will have to order another.
Good news, parts from FastTech and INT Outdoor showed up.
Whaaa… my fingers are getting sore.
What size lens is that? I may have something you can use
It’s 23mm FastTech sku 1187600. I have to back up a little, this a glass lens, and the lens chipped instead of cracked. If you have it, I could send a few bucks, otherwise I will put it in the next order.
I wish I could help you out with the monster copper fittings you need. I saw some good size copper tube up at the second hand store the other day while looking for a 3/4” drill bit. Someone had made a couple grease guns, using 1-1/2” or so copper for the body.
I have a 23mm plastic aspheric lens I can ship out to you. Pm me if interested
I have (or should have, I can check when I get home), a glass aspheric, if you want that.
I will have to verify when I get home, but I have several different sizes lying around.
I appreciate the assistance, but I’ve decided to order another glass one. If that doesn’t arrive in a decent amount of time, I could take you up on your offer though.
Edit: Didn’t see Old Lumens reply there in time. I’ll take you up on a glass one, if you have one. Thanks
If it comes near deadline and you don't got it yet and Justin does not have one let me know.got no problem sending it out
I like these aggressively adventurous mods. Easy is for pansies. This contest is a great idea and the mods should be difficult. I plan on using all the time available and hope it works by the end. 
edit going by salvage yard tomorrow and will check for copper rod.
The tortoise is checking back in. I am amazed at the ingenuity of the handbuilds presented thus far, not to mention the fine workmanship. Well done!
The zoomie function of a flashlight has made for more thinking and less doing. I hope I have a grip on it. Lots of parts to make.
Added a few pics. One shows my rethinking of the pill. I’ve incorporated a 3/4” pipe “pill extender”. The extender serves as the inner tube of the zoomie, and will serve as the fixed part anchored to the flasklite body. As a byproduct, the extender should give some heatsinking too.
I shouldn’t worry about the pace too much, I haven’t even started other than to wire a test circuit. Looking forward to more pics’n’progress 
This is coming along nicely. You have a wonderful assortment of different tools there you are using.