Maglite XHP50 Mod

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dentillozie
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Location: belgium
Maglite XHP50 Mod

i had an old LED maglite that needed an upgrade.
This is my first Maglite mod and it took a lot more time to do then i expected.
But im very happy with how it turned out.
The LED i am using is a XHP50 J4 1D

i started by taking it apart. The LED model uses a torx screw instead of a hex screw.
I dont have a torx screwdrivers so i decided to drill out the screw.
drilling out the screw made the stock switch not usable anymore. So i bought a toggle switch from amazon.

the driver i used is from a TR-J19. it puts out a constant current of about 4A
I had to modify the driver in order to make it less high.

Picture of the whole driver/switch assembly.

for the heatsink i used a old Intel heatsink. I had to cut off all the fins. A friend of mine then turned it to size.
I wanted to keep the “focus-defocus” ability of the stock light. I had to make a pillar that would fit in the hole of the reflector.
for the pillar i used a Noctigon MT-G Board for the base with 4 copper discs soldered on.

to make sure the pillar had a good contact i drilled some holes and screwed the board to the heatsink.
I also drilled wire holes.

After putting everything back together i encountered some problems. the light kept shorting out and the wire would desolder themself.
I found out the cut down sinkpad had the Positive side in contact with the base.
To fix this problem i cut down a noctigon and reflowed the XHP50 to the new board.

Some Beamshots compared to a Modded TR-J19 (3A per led/ 2leds dedomed 1 domed)
first picture is the maglite, second the TR-J19
High:

Mid:

Low:

Thanks for reading!

DenTilloZie

EU based flashlight modder. If you need any modding work done, make sure to PM me!

some of my mods:

- convoy meLd 4

XHP50 Maglite Mod

UF-1405 Mod

TK35 (clone) to TK35UE

Edited by: dentillozie on 12/24/2015 - 18:49
MRsDNF
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Location: A light beam away from the missus in the land of Aus.

Nice mod and thanks for sharing. Your mode spacing looks about perfect to me. What driver are you using?

My current and or voltage measurements are only relevent to anything that I measure.

Budget light hobby proudly sponsored by my Mastercard and unknowingly paid for by a hard working wife. 

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

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

 

dentillozie
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Joined: 10/22/2013 - 11:25
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Location: belgium

MRsDNF wrote:

Nice mod and thanks for sharing. Your mode spacing looks about perfect to me. What driver are you using?


I dont know the exact model but it came from a TR-J19
I had it laying around from when I modded that light.

EU based flashlight modder. If you need any modding work done, make sure to PM me!

some of my mods:

- convoy meLd 4

XHP50 Maglite Mod

UF-1405 Mod

TK35 (clone) to TK35UE