Lathes? Lathes? We don't need no stinking Lathes! - 2AA Maglite Mod

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Old-Lumens
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Lathes? Lathes? We don't need no stinking Lathes! - 2AA Maglite Mod

Well I had to do the weekly grocery shopping at Wally World on Sunday. Lo and behold, there was this nice display of Maglites - A 2AA & A 2D Incan with batteries & belt holder packaged all together for $19. Well I had no choice... you understand. Two Mags waiting for a nice Modder to come take them away.

I'm going to put 3AAA batteries and a Q5 emitter, with a heatsink, in the 2AA Mag. Wait! You can't do that! Or can you? I can.

Here's a couple of photos of what I'm doing:

So here's the lonely 2AA sitting next to a couple of files and a 13/32" drill. The light wanted to go back to Wally World at this point.

2aa1

 

 

Now if I just drill out the endcap a little...

2aa2

 

and now I gain 10mm of space for an AAA battery to sit in. The overall depth is about 12mm, but a short springy thingy will go in the bottom.

2aa3

 

 

Ok, let's tear up the head next.

2aa4

With a couple files and a lotta love, I have cleaned off the threads on the head, just down to where the threads are not visible any more. The OD has to match the copper fitting, so that the fitting is a "press fit".

2aa5

I didn't bother to press it on. I need to do a bunch of stuff before I put it on, like making a heatsink, cutting the fitting to length, etc...

That is a 3/4" Copper Union in case you want to know.

 

Day 2

I wanted to hold the 3AAA eneloops tightly and I had some rigid plastic tube (too small), so I split it and now it works as the battery holder.

012aa

 

Place the bottom battery in the tail cap (no spring needed as the battery butts right up to the bare aluminum).

022aa

 

Slide it into the body and there we are! Oh, notice the copper trim ring between the tail and the body.Wink

032aa

 

The other end - The battery sticks up a little far doesn't it? That's why the copper extension for the head. Once I remove some coating from the threads on the body & head, this will power on by a twist of the head.

042aa

 

Heatsink Time!

The heatsink is made up of copper plumbing parts. A 3/4 to 1/2 inch adapter, a 1/2 inch cap, a 3/8 inch cap and a 24 gauge piece of flat copper sheet, for the emitter to sit on.

052aa062aa

 

The contact end is a plastic washer with a brass insert that came from a hobby shop and is for a model airplane. The positive wire is soldered into the brass and everything is glued down using Arctic Alumina.

072aa

It's all got to be cleaned up, but you get the idea.

 

The heatsink slides into the copper extension and the modified plastic reflector fits flush. I opened the hole in the reflector and sanded the bottom to make it thinner, so it would seat farther down around the emitter.

082aa092aa

 

There's still a lot of work. I have to make the bezel fit the copper, so the lens can go on top, but that's for another day.

 

 Day 3

It's finished! I just used Arctic Alumina to glue the heatsink in the copper extension and pressed fit the extension to the head. Slip in the batteries and just a twist to light it up!

Here's a couple shots of the finished light.

 done1

done2

done2

I did an OP finish on the reflector with Krylon Clear Acrylic and I ran a bead of epoxy around the top of the reflector and pressed the lens in place. Worked out ok.

 

And here's a video of the beam shot.

 

 It's ok, not great, but ok. I liked the beam better with no reflector at all. I am sure the next light I do, will have no reflector, as I like not having any hot spot or rings in a beam, just one solid, perfectly round lighted area. The hardest part of the whole thing was getting the head and body to make contact on the threads, so that twisting the head turned the light on. I wish I could strip the anno off the threads, but I just used sandpaper to brighten them and then laid a small strip of desoldering braid in the threads. That was what did the trick. It is harder to turn, but you only have to turn it about 1/8 turn to on or to off.

 

If anyone wants it, it will put it up for sale for a few days.

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

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Edited by: Old-Lumens on 12/07/2011 - 15:04
Smelly
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More pills!

jacktheclipper
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Now this I can't wait to see ...

You go Old-Lumens !

old4570
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I did a very simple mini mag mod [ a long time ago ] , and I have another MMag waiting on a mod ...

Just waiting to free up an older XP-E R2 emitter ....

But this looks like its going to be a very interesting mod , go Old-Lumens , go ... 

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The resulting sound may , or may not be worth listening too ….

 

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I would say that it takes a pretty large set to show the beginning of a mod like this before it is done. What if it all goes to crap? Old Lumens doesnt care, Old Lumens is bad a--. Nice job OL!

Piers said " ....but who wants enough light, when you have the option for far too much "

JohnnyMac
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Langcjl wrote:

I would say that it takes a pretty large set to show the beginning of a mod like this before it is done. What if it all goes to crap? Old Lumens doesnt care, Old Lumens is bad a--. Nice job OL!

LOL!  O-L reminds me of the honey badger.  "Honey badger doesn't care. Honey badger don't give a s--t!"
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Stop referring to my private parts.EmbarassedSealed

I must think I have big B***s? No, I just measure it all ahead of time and sit down and see if normal hardware copper will fit. I was lucky that it was a Maglite AA, otherwise stuff wouldn't fit so well. Once I could visualize it as I measured, it all fell into place, but that was always my talent, seeing something finished before it was started and knowing it could work. Rube Goldberg maybe, but "On the Cheap" has to have a little Goldberg in it...

Thanks for watching the thread!

Tongue Out

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cabfrank
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can't wait to see it finished, very nice!

dthrckt
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mind sharing where you get copper sheet?

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dthrckt wrote:

mind sharing where you get copper sheet?

In the thread for the SAiK, there's links to that stuff. I buy small quantities 3"x3" or 4"x4" sheets for $3 bucks or so.

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Essexman
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I'm really having fun reading your builds Old Lumens, keep up the good work!

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Essexman wrote:

I'm really having fun reading your builds Old Lumens, keep up the good work!

  I try not to take myself too seriously in a forum, it's easier on the rest of you that way.Wink.

Besides, it's supposed to be fun or it's not worth having the hobby. I do take it too seriously for real, but y'all don't get to see that side.Surprised

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esrevenge
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Awesome work...the copper fitment ring looks great

raccoon city
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JohnnyMac wrote:

"Honey badger doesn't care. Honey badger don't give a s--t!"

crackupHoney badger made my day.

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JohnnyMac wrote:

LOL!  O-L reminds me of the honey badger.  "Honey badger doesn't care. Honey badger don't give a s--t!"

Badgers!, Badgers!, We don't need no stinkin Badgers!

 http://youtu.be/gx6TBrfCW54

From the Movie UHF. Yes I saw UHF.

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All done and working. Pics and a video in the first post, at the bottom of the post.

Put it up for sale to see if anyone wants it.

Have fun!

Justin

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Chicago X
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Very nice work, thanks for sharing. 

I must say, the copper trim ring really sets this build apart. 

FWIW, I believe that the deeper 'Rebel' reflector may be better suited for LED swaps. 

Once again, excellent job !!!

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agreed, i will definitely copy that trim ring idea:)  found the link for copper sheet, thanks - cheaper than onlinemetals.com.  their sample pack has more mass but $9 + shipping (was 8.64 for me).

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skippyman
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Nice Build. I’d like to try something like this for my first foray into Modding.
Did you use any kind of driver or is the emitter connect direct to the 3 AAA’s

Thanks

Regards,
Skip

Rufusbduck
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Pretty sure it’s direct driven.

Three Tanna leaves to give him life, nine to give him movement. But what if he eats the whole bag?

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mapache
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Thanks for the gravedig , would have never seen this otherwise. I have a few incan mags I would like to do something with, one day.

strayz
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I am interested in what he has or is going to do with that Double D mag light…

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Probably listed Here

Three Tanna leaves to give him life, nine to give him movement. But what if he eats the whole bag?

Scott