Making a cutdown 1D Mag-lite LOTS-O-PICS !

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Chicago X
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Making a cutdown 1D Mag-lite LOTS-O-PICS !

Hi folks,

I never appreciated how much work went into making a cut-down 1D Maglite, until I tried it myself.  It turns out that the cutting is the easy part!

 

First we start with a stock 2D Mag:

 

 

Off comes the switch cover:

 

 

A torx T8 key is required to remove the light engine from newer lights.  This one was ground down to fit the extremely small opening in the switch body:

 

After loosening the screw, the switch gets pressed in slightly and the entire light engine slides out the rear of the battery tube:

 

Here's what's left after head/tailcap/light engine removal:

 

 

Masking tape is your friend.  The covered bit is what will be kept, and the rest lopped off:

 

 More to come.

http://wardogsmakingithome.org/index.html

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Edited by: Chicago X on 12/06/2012 - 19:46
Chicago X
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Here's a shot comparing an incan Mag (in red) to a LED Mag (silver.)  Please note the difference in threaded area between the two:

 

 

The cut-down tube gets flipped around, and the head becomes the tail...and vice-versa.  This preserves the knurling, and looks best, IMO.  Here is the newly-threaded tailcap section, on the left:

 

The other end gets a set of threads and o-ring groove:

 

Newly threaded tube on left, stock LED Mag center, and stock incan Mag on right:

 

 

You now have a shorty host:

 

 

Side-by-side with a stock 2D:

Total height is around seven inches/18cm:

 

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Chicago X
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Reserved

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:bigsmile:

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Oh just wait until you see what is to come!  The threading is pure excellence! Wink

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Stradivarius. He kinda makes me sick. Tired Big Smile

“When I buy something in bulk you should prolly buy at least one too.”…..“They that have light shall rule the night.”…..“Flashaholics feel depressed without darkness.”…….“I’m a very terminal torchaholic. My entire life just flashed before my eyes

Chicago X
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Updated with threading pics.

http://wardogsmakingithome.org/index.html

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nitro
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Very nice can’t wait to get a bigger lathe Smile

jacktheclipper
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!

mattthemuppet
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wow, you have a really neat work bench! Nice work on the body too, I wish I could cut threads on my lathe, it’d make a lot of projects simpler.

garrybunk
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Nice!  What's the plan for a switch?  Tailcap switch?  Or a twist the head / tail?

-Garry

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Chicago X
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Thanks for the kind words, guys !  There are seven machining operations required to make this host, and a few more to finish a complete light.

 

garrybunk wrote:

Nice!  What's the plan for a switch?  Tailcap switch?  Or a twist the head / tail?

-Garry

This one will get a tailcap switch.

http://wardogsmakingithome.org/index.html

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Finally, folks, you now have a real life source (right here in BLF), for cut down Maglite hosts!!! I have been waiting for this for many moons. I thought it would never come! As you can see, the man does excellent work and is meticulous in his methods.

It's good to see that BLF now has a way to get 1D hosts for their modding. Believe me (since I know about this stuff a little bit), it is well worth going to Chi-X and asking him to make you a host like this instead of trying to make one yourself. I have made enough myself, to know the extensive learning curve and one made like this will always be 10 times better than hand made! Believe it!

 

Thanks Chi-X for doing such a good photo show and tell.

I do worry though, when a big guy like you comes around wearing rubber gloves.Surprised

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gords1001
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Nice work chi-x, there’s no dust collecting on THAT lathe, that’s for sure. 8)

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Chicago X wrote:

This one will get a tailcap switch.

I'm excited to see what kind of switch you go with.

I believe I paid something like $30 or $40 to have a Mag cut down and rethreaded.  I thought that was a lot at the time, but I've realized it's going to take me a lot of time and patience to do that on the lathe myself.

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Old-Lumens wrote:

I do worry though, when a big guy like you comes around wearing rubber gloves.Surprised

I shook his hand, so I agree completely Smile

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Outstanding job on the machining, specifically the threads both inside and out.  Have the guts picked out for this one yet?

Anyone else think this  -

"Two by two, hands of blue..."

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Nice job Chicago X. Old-Lumens sprang to mind when I started reading this and yep there he was. Are you happy with the new purchase? (The lathe).

 

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.

 

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thats nice… i like how you saved the knurling on it the way you did. only thing i would have done different (no lathe and no skill with one, so no room to talk really Silly ) is save the side switch… but im sure whatever you have in store is going to be amazing

also, now that i think of it… if you did save the side switch, you wouldnt have been able to keep the knurling the way you did, so i guess its a catch 22 on that one

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Pulsar wrote:
thats nice... i like how you saved the knurling on it the way you did. only thing i would have done different (no lathe and no skill with one, so no room to talk really Silly ) is save the side switch... but im sure whatever you have in store is going to be amazing also, now that i think of it... if you did save the side switch, you wouldnt have been able to keep the knurling the way you did, so i guess its a catch 22 on that one

The 1D can be done with or without the side switch. The overall length changes since the switch stays, but it can still be done. The knurling can still be there, but it would not be as balanced as it is this way. It is, as they say, "doable".  The OAL of the knurled section is (if memory serves), about 75mm, which works out ok, for either a 3 or 4AA holder or a 26650. The space between the knurl and the switch is (about 20mm??), so it would mean cutting right at the back end of the knurl, for proper OAL with a Std tail cap (which is about 40mm deep with spring compression). I've slept since then, so I may be wrong.Wink

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JonnyC wrote:

Old-Lumens wrote:

I do worry though, when a big guy like you comes around wearing rubber gloves.Surprised

I shook his hand, so I agree completely Smile

He's wearing gloves?  I just assumed he dropped his wallet or something in a port-o-potty and had to fish it out with his hand.  :~

Tongue Out

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Of course, people are noticing just how many Maglites are standing in the background, in that "hand photo". Looks like he's got a good start on a run of them.Wink

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All I know is that one of them is mine.  I'm THRILLED!!! Wink

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Old-Lumens wrote:

Of course, people are noticing just how many Maglites are standing in the background, in that "hand photo". Looks like he's got a good start on a run of them.Wink

Oh damn, I didn't realize those were all cut down already Smile

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Chicago X wrote:
A torx T40 key is required to remove the light engine from newer lights.  This one was ground down to fit the extremely small opening in the switch body

Don’t you mean a T8

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The balanced looks resulting from the non-knurled band on the tailcap end…man!
I have access to some good machinery but I’ve never attempted cutting threads. If this was a class I’d be frantically taking down notes.

Keep up the super work C-X.

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Gtamazing wrote:
Chicago X wrote:
A torx T40 key is required to remove the light engine from newer lights.  This one was ground down to fit the extremely small opening in the switch body
Don't you mean a T8

Thanks for the correction - I will update the OP.

Grumble grumble damn dyslexia.


 

JohnnyMac wrote:

 

He's wearing gloves?  I just assumed he dropped his wallet or something in a port-o-potty and had to fish it out with his hand.  :~

 

Tongue Out

 

 

 

 

 

I wouldn't normally wear gloves while machining (for safety reasons) but I was trying to keep oil/grease out of some stitches on the left hand.

 

Match wrote:

Outstanding job on the machining, specifically the threads both inside and out.  Have the guts picked out for this one yet?

Anyone else think this  -

"Two by two, hands of blue..."

No internals specced yet, but nice Firefly reference ! 

 

 

MRsDNF wrote:

 Are you happy with the new purchase? (The lathe).

If I had known how much fun one was, I would have picked one up years ago.  Now I need to sell a few lights to fund a mill.  Wink

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i bet some HUGE DEEP mag heads could fund your mill 0:)

not that i could afford one, but id be here drooling

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As soon as I saw title and author I had to read this. Really nice work CX. If you milled down a section of the tube, could Justin do a woody inlay? Then you could have a side switch and eliminate the knurling altogether.

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Slim Pickens wrote:
Keep up the super work C-X.

 

Thank you sir !

Pulsar wrote:
i bet some HUGE DEEP mag heads could fund your mill 0:) not that i could afford one, but id be here drooling

Stay tuned....

 

Rufusbduck wrote:
As soon as I saw title and author I had to read this. Really nice work CX. If you milled down a section of the tube, could Justin do a woody inlay? Then you could have a side switch and eliminate the knurling altogether.

I don't think it would be a problem turning the knurled part down by the thickness of some wood veneer.  I'm ready to take such an order at any time.  Wink

 

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If anyone needs some stock Mag parts, please shoot me a PM.

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