Maglite Solitare - What to do? Maybe a TIR, a Nichia and a 10440 - Build thread

12 posts / 0 new
Last post
Old-Lumens
Old-Lumens's picture
Offline
Last seen: 3 years 3 months ago
Joined: 11/04/2011 - 11:39
Posts: 7478
Location: Tyler, TX, USA
Maglite Solitare - What to do? Maybe a TIR, a Nichia and a 10440 - Build thread

Hello,

I decided to put a TIR optic in a Maglite Solitare. I am also using a Nichia 219 and this light will be made for a 10440 Li-ion.

Here's the build thread:

s1

I start with a stock Solitare and tear it down, to do some mods.

 

s2a

 The first thing to do, is remove the stock reflector and lens. Now I have a time getting these out. They never will just pull out, so I have to do some massaging.

s2b

 I take an exacto knife and pry out all the locking tabs on the bottom of the reflector. Then I just use a pair of needle nosed pliers to pull the reflector out. The lens just drops out after that and I leave the O ring in place.

 

s2c

 The TIR optic came from CNQG. It is a 11.8mm diameter TIR optic and it is plastic, even though the CNQG description states glass. They call all of them glass, but it's a normal TIR plastic optic. It is listed as a 20 degree optic.  11.8mm is too big to fit into the Mag head, so I use a sanding block to remove material from the large outer diameter, till it fits in.

 

s2d

 That's a poor shot, it's really not torn up as it looks.

 

s3a

 The next thing is making the Nichia fit into the light. I am making this light just like the 2AA lights, where you twist the head to turn on and turn off the light. Here I have cut a piece of .008" copper sheet, to back up the Star. The star is 10mm dia and so is the copper. I have soldered the ground wire directly to the copper, as the copper will be ground.

s3b

 Here's how it fits together. I still need to make the positive connection.

 

s3c

 The positive connection consists of a piece of plastic tube, that will sit down in the top of the body, just as the original contact did. On one end is another piece of .008" copper sheet in the form of the positive contact. I have soldered the wire to it and the wire goes thru the center. This plastic tube is hard tube and it is 1/4" in OD and 3/16" ID. This fits down into the top of the body, but the top of the body has to also be drilled to take this plastic tube. I used the next size up from 1/4" to drill the body. The plastic is also notched so the positive wire will go under it and up into the hole for the emitter star. The notch gives the room for the wire to fit there. I just used a file for that notch.

You could use smaller tube, that would fit the stock hole, so you didn't have to drill (open up the hole in), the top of the body. I didn't have any smaller tube, so I used what I had.

 

s4a

 Here's the top of the "pill" with the wires in place.

 

s4b

 Here's the bottom. You should be able to see how it works now. The larger copper ring touches against the body, making the negative contact. The center post touches against the battery positive, making the positive connection. As the head is turned out, the whole thing moves upward, due to the spring pressure on the battery and that breaks contact on the negative ring. When the head is turned in, the ring makes contact with the body and the light turns on.

The length of this positive contact post has to be exact and I am guessing a little with this first one. I went by the stock dimensions of an unprotected 10440, but I actually messed up and went too long. It is 11mm long right now and it needed to be no more than 10mm max. I Guess I need to stop this late night work (yawn). Anyhow, I feel the proper dimension would be better at 9mm for an unprotected 10440 and 7mm for a protected 10440.

I used Arctic Thermal Adhesive, to hold the tube to the copper plates at both ends. I actually filled the tube up with it, to help make it a better hold.

 

s4c

 You can see how the copper contact plate (negative) will touch the top of the body, to make contact.

 

 

sbs1

 I am testing with two AAA Alkalines and a piece of wire to ground it. It works! I have the wrong camera out here with me and the photos do not do justice, since I can't do manual settings, so here's a couple meager shots on automatic settings. It is brighter than the photos show and I can't wait to see how bright it will be with a 10440.

 

sbs2

 

sbs3

 

 That's about it. I feel many of you could do this mod if you have a little patience. It's not horribly hard, it just takes some time and patience.

 

Match, the light will be on it's way to you soon, so you can check it out. Have fun and let us know how it works with a Li-Ion.

 

My PayPal address: oldlumens (insert the @ sign here) gmail.com

My YouTube Flashlight Video Channel

The BLF Modding Links Thread 

http://imageshack.com/a/img922/1374/jQ2wdL.jpg

 

ChibiM
ChibiM's picture
Offline
Last seen: 4 hours 2 min ago
Joined: 05/09/2011 - 10:25
Posts: 6245
Location: Holland

This might be a good base to finally start modding my wife’s unused and broken mini 2xAAA mag.
Thanks for posting!
I wonder if there is something you Can’t do with a Mag!? Big Smile

MRsDNF
MRsDNF's picture
Offline
Last seen: 3 hours 49 min ago
Joined: 12/22/2011 - 21:18
Posts: 13256
Location: A light beam away from the missus in the land of Aus.

Nice mod Old-lumens. I find it amazing how much light you can get out of little lights more so than the larger ones. Good stuff.

 

djozz quotes, "it came with chinese lettering that is chinese to me".

                      "My man mousehole needs one too"

old4570 said "I'm not an expert , so don't suffer from any such technical restrictions".

Old-Lumens. Highly admired and cherished member of Budget Light Forum. 11.5.2011 - 20.12.16. RIP.

 

ChibiM
ChibiM's picture
Offline
Last seen: 4 hours 2 min ago
Joined: 05/09/2011 - 10:25
Posts: 6245
Location: Holland

BTW what size is that star/board? 10mm?

Old-Lumens
Old-Lumens's picture
Offline
Last seen: 3 years 3 months ago
Joined: 11/04/2011 - 11:39
Posts: 7478
Location: Tyler, TX, USA

ChibiM wrote:
BTW what size is that star/board? 10mm?

 

Yes, 10mm

My PayPal address: oldlumens (insert the @ sign here) gmail.com

My YouTube Flashlight Video Channel

The BLF Modding Links Thread 

http://imageshack.com/a/img922/1374/jQ2wdL.jpg

 

Match
Match's picture
Offline
Last seen: 3 years 11 months ago
Joined: 11/14/2010 - 11:57
Posts: 1488
Location: South Carolina, USA

Nicely done Justin, and I look forward to sharing my thoughts on review.  I'll update here when completed.  Thanks for the opportunity.

agenthex
agenthex's picture
Offline
Last seen: 6 years 5 months ago
Joined: 07/14/2010 - 04:49
Posts: 3070
Location: Merica

These sleeper mods are pretty cool. One day someone is going to put 9 xp-e’s in one of those 9led showerhead lights.

Reading this makes you smarter: http://lesswrong.com/

texaspyro
Offline
Last seen: 9 months 1 week ago
Joined: 04/29/2011 - 12:43
Posts: 4593

Welcome to the lithium side of the force, Old One J)

Old-Lumens
Old-Lumens's picture
Offline
Last seen: 3 years 3 months ago
Joined: 11/04/2011 - 11:39
Posts: 7478
Location: Tyler, TX, USA

texaspyro wrote:
Welcome to the lithium side of the force, Old One J)

I figured I had to make a few Li-ion lights fer all yall.

After Match has a chance to see if it blows up or notSurprised, I have 3 or 4 more to make if people want 'em.Wink

My PayPal address: oldlumens (insert the @ sign here) gmail.com

My YouTube Flashlight Video Channel

The BLF Modding Links Thread 

http://imageshack.com/a/img922/1374/jQ2wdL.jpg

 

scaru
scaru's picture
Offline
Last seen: 3 years 3 months ago
Joined: 03/22/2012 - 13:36
Posts: 6946
Location: Virginia

Looking forward to the for sale sign. Big Smile Let's see if I can beat my past record of 2 minutes. Wink

Slim Pickens
Slim Pickens's picture
Offline
Last seen: 2 days 35 min ago
Joined: 04/28/2012 - 19:50
Posts: 1199
Location: Maine

You can lego the head from a 2AAA Minimag onto a Solitaire body (but not very nicely the other way around, since 2AAA body has more thread). Thought it was kinda cool, had a nice shape. My iPhony apologizes for the crappy image quality.

May be an interesting option for DD Solitaire builds of yours, Justin (even if it’s simply for the sake of options!)

Old-Lumens
Old-Lumens's picture
Offline
Last seen: 3 years 3 months ago
Joined: 11/04/2011 - 11:39
Posts: 7478
Location: Tyler, TX, USA

Slim Pickens wrote:
!{width:50%}http://i1167.photobucket.com/albums/q626/Drew-SP/photo.jpg! You can lego the head from a 2AAA Minimag onto a Solitaire body (but not very nicely the other way around, since 2AAA body has more thread). Thought it was kinda cool, had a nice shape. My iPhony apologizes for the crappy image quality. May be an interesting option for DD Solitaire builds of yours, Justin (even if it's simply for the sake of options!)
That's interesting, I will have to play around with that, the next time I get an AAA light. Can't find them in the stores around here any more. Have to order them, so I don't get many, but it looks like another good option.

My PayPal address: oldlumens (insert the @ sign here) gmail.com

My YouTube Flashlight Video Channel

The BLF Modding Links Thread 

http://imageshack.com/a/img922/1374/jQ2wdL.jpg