New Convoy Deep Carry clip

If you’re worried about scratching the anodizing when unscrewing the battery tube,
slip a bit of paper under the contact point before you start turning the tailcap.
No problem.

(write your name and address and “REWARD FOR RETURN” on the piece of paper, and slip it into the battery tube while you have it open — if someone finds your flashlight, they might get in touch)

This is with minimal actual use, but you can see scratching beginning. I think this is inevitable if you want a pocket clip.

Of course, widening the gap slightly would make room for me to apply the heat shrink tubing fix, like I did with my old-style screw-on pocket clip:

I find if you just pinch the back of the clip to the endcap while unscrewing you can lift the tip up enough to not rub on the body.

I actually like a relatively light clip tension but I think most people like them stiff. As long as there is a way to bend the clip in one way or another to adjust it thicker metal wouldn’t be a bad thing.

As to that little right angle that interferes when slipping the clip over the edge of a pocket, you should compare the OrcaTorch T11, which has a smooth transition there that avoids the problem completely:

+1 I agree. That's a better way to do it.

1+

I was just thinking about that.

Also how about bringing the end of the entrance ramp up a bit. Up to the level of the rest of the clip.

And adding a small straight section at the tip. Say 3mm. I can do a drawing.

Thanks hank. That’s about what I had in my head for that little ramp area which is now a snag point on the Convoy clip. That picture helps. I think that’s essentially what Halo was getting at too. My concern with that type of design is the thinner band we have to work with as the attachment point. You need to add a little rounded relief into the metal at the “T”. You can see right where they did that with the Orca clip and it looks spot on but the Orca clip looks like it has around 4-5mm to work with where we have 2.5mm. That doesn’t leave enough metal for us to add that necessary “U” notch in the metal at the proper point that eliminates or drastically reduces the stress-fracture point. Another thing I considerred is just widening the clip groove in the S2+ and eventually the rest of the S series so that we can design a truly proper clip. That however doesn’t do anything for all of the lights that we already have. I appreciate all the input everyone has given here. More thinking to do…

Just found this thread and I have a question. Will this clip fit any of the SolarForce hosts sold by MTN Elec.? I’ve been looking for a good deep carry clip for my L2T/P lights. Thanks.

Yea, quietly I knew that would kill it. The width of the clip-on band is so narrow.

How about this method of creating a ramp?


Nice idea Halo. If it’s done right that would work.

I agree, that is a very nice design, and unlike any ramps or anything it will be super close to the light body so even thin fabrics can’t get caught under the ramp. I wonder if the triangular areas connected to the ramp could be tilted outward slightly. This I think would make the ramp a lower angle but more importantly it would make the bends in the metal there a larger angle so it can be formed easier.

All the angles can be adjusted. If I had some scrap sheet metal I would do an example of how you’re suggesting. Just easier to adjust and hold angles even on both sides with metal. Anyone have a spare can of soda, pop, beer?

Yep, very nice design from Halo. I hope this gets worked out.
Anyone have access to one of those super sheet metal cutters that use water jets or lasers?

Aside: I just tried to open out the 180-degree bend in one of my Convoy clips.
It eventually snapped right off, in the middle of the 180-degree bend.

This point is a concern to me:

Walking near vehicles… I’m always paranoid about the tip of a pocket clip scratching the paint when I’m walking past something. Just something to keep in mind.

Like the Manker e11… I dislike the clip!

Anneal it first to reduce the brittleness. Take a blow torch to the bend. Heat till glowing hot. You could also try a torch lighter if you don’t have anything larger.
If you find that it doesn’t hold as tight onto a pocket as before you can re-harden it. Bending (at any part that was red hot) can work harden it. You’ll feel it getting harder to bend. Or you could try tempering it in your oven at 148-205°C (298-401°F).

Heat shrink! :partying_face:

A lot of good input here guys. I love the design concept halo posted but I’m concerned about those angles. If they aren’t done just right we have a whole lot of scrap metal and I don’t know if Simon’s source is equipped to properly pull off those angle bends. Still, I will present that to Simon as one concept to see if he thinks it could be achieved. One area of concern I have in that design is you’re starting almost 180 degree bend coming out of a circle so you have to flatten the circle as it bends. Probably not the best explanation but I don’t have time to do a drawing right now. The clip redesign may take quite a while. It took a long time for the first one. A completely new design could take several months to get right so patience will be required on all sides. For now I’d just be happy opening the gap to fit a hat bill. This is top of mind for me because I had Simon add a groove in the head of the S2+ for the reverse hat mount. You should see it in the release of the next model S2+. It should work really nicely on the shorties especially on a tricked out shorty like the ones vestureofblood is selling now. Those are way cool. :sunglasses:

How about anodizing instead of the black paint?

Hmm, I don’t think I have any 180° bends. 90° should be the highest. And those could be reduced as Scianiac suggested.
Maybe the bottom of the ramp? Corner. Yea, that spot is a concern. Probably better to not have the ramp go all the way down, not meet the flashlight. That way we can avoid that corner.

Oh yea, Of course. Major redesigns are maybe shooting for version 3.
Perhaps even hold off presenting it to Simon since it could be improved. Better to present him with a mulled over version.