2AA Maglite 90 degree Swivel head mod - The second attempt works! Beam shots are up

Good question on how to do the screws up. Drilling holes in the side I suppose is out of the question. My first problem would be how to get the holes in the right position so the two halves stay aligned in all positions. My first thought is (dont know how to make it work) is the plastic plug type clips they hold dashboards and grills in these days so that the two halves press together. I no doubt know you will come up with some sort of black magic. Looking really good.

As with the contest it’s always fun to see how others overcome difficulties.

Interesting thread, looks like it’s coming together nicely. Look forward to seeing it finished.

Detents for a position and a stop? Gotta keep from twisting the wire too much too right? A detent or two for position points and a stop at straight and 90º so it stays within that short pivoting range will keep the wire intact. Hopefully. Otherwise, it’d take a continuous positive/ground rotating connection between the 2 plates.

A nylon locking nut will keep the screw from loosening or tightening up.

I might have a solution for your screw dilemma…… Solder or glue the nut fast so all you have is the screw to deal with and that should be no problem seein its a Philips.

Amazing work, seriously amazing.

Good choice with the TIR optics too.

I just used JB Weld on both ends of the screw. Filled up the ends, leaving just the wire hole. It ought to hold fine. Takes about 24-48 hours before I will do anything else with it. Besides another cold front is coming in and I can't do anything at work any more, so it will wait till it warms up again.

Not sure about the latest update but is this quits? Or is the JB Weld solution the latest status?

Sorry to hear it didn’t work out. I have to say though, your “fails” are far better than my successes!

Scribe a line and drill the screw hole first. Equidistant from that hole and on the line make 2 marks. After you connect the two sheets but before you solder them to the angle tubes hit the marks with a center punch. Rotate 180 and the punches line up again. Solder to tubes exactly in the right place. Easy to say, hard to get right. Other problems ensue, light goes to dumpster.

This could be a joint effort build OL. It sounds like RBD is itching to finish it of. :wink:

Hey? What? It doesnt sound like it hit a wall to me. He has used JB Weld to lock the pivot in place, sounds to me like it would be a substantially thick layer (a significant blob if you like) and therefore will take a fair amount of time to cure fully. When the weather warms, and he has time at home, progress will resume.

No bust. Just a delay. Did I miss something?

Some things in here don’t react well to bullets, or dumpsters, or hammers. How recoverable it is may depend on how much of a catharsis was required. I am intentionally making light of a painful situation with an utter lack of tact. It’s much easier than trying to say “the right thing”. Please accept my appology if you feel it’s needed OL.

Nope, I stand corrected. I didnt check the thread title, or the OP, so I never saw the changes from the JB weld post.

The problem was the screw. It can't be a screw, It needs to be something like a rivet. I believe the manufactured ones use a rivet with a hole in the center. Anyhow that would be needed, but I can't find one with a hollow in the center and one that small.

Detents stops will not work well. There needs to be something better than a detent. I would have possibly used a pin in one piece, with a slot in the other, so it could pivot from straight to ninety, with the pin stopping at either end of the slot. It would work if there was room. Everything is so small and I think the other manufactured lights, just make the inserts out of plastic and that makes sense.

Anyhow, if I had different tools, I might have made it, but it is a little too small and difficult to do with my skills and the tools at my command. At least whoever does make one, can learn from my mistakes.

I am sorry to hear that Justin.

Maybe if yóne were to try and use 2 spring washers, one under the head of the bolt and one under the nut. Tightened just right they should be able to take up any slack from the screw thread loosening 1/2 a turn.? Anyways I know I am just spitballing here since I do not have the parts in front of me and you do. It is too bad though. One of a kind project for sure.

Better luck next time O-L. :-)

I can see how that might work and spent the last few hours with this stuck in my head. Your mods to this to me all the time, making me think sideways and inside out. The Master of Miniscule has consulted the oracle of lost sleep and was blessed with AN ANSWER. Your tools, your idea, no plastic.

Not sure what the problem is. Grind the threads off the screw where the contact is made at the joint, makes it just like a rivet. Use a brass screw, solder the nut on. Just like a rivet. Problem? Desolder the plates from the tubes, put them together where you can work on them, then put the tubes back together. Small get’s big get’s small.

Beats me, just ideas.

Go for it.

Sorry the mod ended before I even got to the thread. How about a pop rivet for the pivot? They're hollow if you use a pin punch or small nail to push out the little expander that breaks off inside. You'd need to rivet the flat plates before soldering to the tubes.