My First Big Mag Mod

Flashlight Modding and DIY Parts
1

Hey all,

Figured seen as I was going to start posting around here I’d just show an old project I did and posted about over on CPF. I’m sure 99% of folks frequent both forums so this may be nothing new. No harm in showing it again anyway! Hopefully some one sees it for the first time and gets a kick out of it :slight_smile:

It’s a 3D mag running a pcb-components.de ‘Senser Extreme’ Boost Driver modified to provide 3.05A to 7 series connected XM-L-U2 emitters. This setup is controlled by the stock switch and ‘Nano Dim V2’ dimmer module (another pcb-component.de product) connected to a 10Kohm pot. The whole rig is powered by a custom built battery pack that utilizes parts taken from a special battery adapter, some PVC tubing and a 2000mAh LiPo 3S battery pack capable of up to 25C discharge. Given this the driver steps 11.1V up to nearly 25V it pulls over 8A from the pack…still yet to do any measurements though. The lens is borofloat because of the heat which you can clearly feel holding the front 15cm from your hand. The optics are a Cree 7 point 12 degree optic.

The pot cover was custom machined but the most important part however is the 100% pure copper heat-sink (which was also custom machined). I designed the heat-sink to fill the entire head of the stock maglite and it fit like a glove. The 4 screw points help with keeping pressure in the head.

Everything is connected with high temp silicone wire. There’s barely any room to move inside the body and head the tolerances are that tight. Anyway….more pics. Sorry if they are a bit small. I had so much I wanted to show but needed to keep the pic sizes and number down.

I had to modify the driver to output 3A….I was pretty nervous doing this as it’s a $50+ driver. I had to mount that 0.1ohm resistor on top of one that was already under the inductor (which had to be removed to get to it). The only issue with this driver is that no matter what brightness I have set before switching it on, it flashes at full power very quickly (not even half a second) before settling to the pre-set level. It’s not too bad, but I have hurt my eyes more than once now…and scared the poo out of a few people I forgot to tell:

Modifying the mag tube, making a collar for the pot (hand filed) and installing BVH’s cover:

Modifying the stock switch, installing and wiring the PWM board and installing the whole lot into the mag tube (No idea why but I put grip tape below the PWM board for some reason):

The heat sink, drilling and taping the mag head for the screws, and test fitting:

Wiring and installing it all up (thermal paste is holding the driver in place), the LiPo pack:

Beam shots. XM-L @ 2.8A left, my mag on the right:

Same as above:

The video below was shot on an iPhone 4S, and the patio light was on. Stock LED MagLite first, then a modified 2.8A single XM-L on low before turning that up high. You can tell when mine turns on It throws damn far as well but only because of pure grunt, so in the yard shot it looks almost like 100% flood. It’s not. The iPhone auto balances it’s metering as soon as mine turns on, so it tones down the difference considerably. Go to 1 minute in to see my light turn on.

Because I can’t get the ‘insert video’ code working you’ll have to click this link

I put a lot of time and money into this project so for it to turn out better than I hoped for is very rewarding.

Thanks for looking!

- Matt

2

Great mod! The dimmer looks very useful and build quality is superb. Well done!

3

Thanks :slight_smile:

I takes pride of place on my desk.

4

WOW! I finally made it into the 1%! Seems like I should have a nicer car.

Personally, Matt, While I wouldn’t hold CPF membership against anybody, but I think that 99% number is a little high. I for one was never a member and I have only gone there once or twice to look at flashlight porn (who’s wife allows a guy to amass 400 Surefires anyway?)

Anyway, very impressive build. I am mechanically inclined and have a hands on job in RL, but I don’t have the talent or time to mod a light. I’m always amazed when I see one of these builds and yours is no different. I look forward to seeing more.

5

I know right!? I see some collections and wonder how in the world these guys afford some of this stuff. I spend too much money on unimportant things like my mortgage, or my car, or sometimes my girlfriend. She hates my lights.

’nuf said.

6

Thats truly impressive.

7

^ Ya, but does she love your girlfriend collection?

8

So many ways that can be taken I have no idea where too start haha.

NightCrawl…I work in aviation and 95% of my work is done with a German company called Comsoft and they’re based in Karlsruhe. Maybe you’ve heard of them? I so badly want to go over there one day to see the place. My colleague loves it (and has been lucky enough to travel there for work twice now).

9

I only meant that so long as you don’t start collecting extra babes, then a flashlight collection should be welcomed by her as a very innocent hobby. I mean, you are not very likely to get into too much trouble at the work bench.

LOL, I don’t see how you didn’t get all that from that one little sentence. :nerd_face: I knew what I meant.

And Matt, for future reference, don’t take anything I say too seriously… I’m a bit of a tart.

10

yes ladies…. he really is THAT good.

well done - i hope one day i have enough knowledge and confidence do something like this

11

Haha…you’re very correct. She also doesn’t seem to mind when I sell one or two lights I no longer want/need and the money buys her dinner!

12

same thing happens to me lol… box from ups arrives… “thats not another light is it honey?! how much!?” me…. “go buy that purse you wanted”…… ok!! lol

13

Seen it over there but still nice project!

14

Right on Matt, this hobby is pretty harmless. Especially the budget lights. Lots of money left over for the truly important things in life and we here chatting to each other rather than trying to pick up cheerleaders in some dirty girl chat room. We only ever get close to that around here when some overseas seller pretends to be a chick who likes camping and someone her asks for a picture; edc, you know who you are.

15

Its a small world. :D

But no, I dont know them. I'm more of an economics guy than aviation. :)

That also made clear why most of your stuff is from german companies.. poti, driver, leds+pcb, optic..^^

16

Damn nice build Matt! The whole thing turned out very clean and professional.

17

Very impressive, Matt, especially the custom heat sink work. I love a good Mag mod.

18

Very nice workmanship, really first rate build. You could use it to do the “shock & awe” on friends that would expect “another Mag”. Thanks for your fine work and the pics.

19

NICE!

Welcome to the BLF and what a unique light you've made. Wonderful construction. Great execution. And it must be able to throw some with that narrow optic. Probably a lot more in real life then what one would imagine when talking about multi emitter lights. Great wrok and thank you for sharing :-)

20

NICE!

Welcome to the BLF and what a unique light you've made. Wonderful construction. Great execution. And it must be able to throw some with that narrow optic. Probably a lot more in real life then what one would imagine when talking about multi emitter lights. Great work and thank you for sharing :-)