Potting compounds?

Flashlight Modding and DIY Parts
1

Been searching around here for info on potting compounds and have learned a lot. I have a couple of mid-grade type flashlights which I would like to try to bullet proof as much as possible for use in bog-out-bags and other such applications as well as just for the fun of it. Some have very accessible internals and some would do well injecting through a syringe mounted catheter. Any specific suggestions for a potting compound? My preference would strongly be for something available in a syringe for easy storage, use and mixing…

So far I have found the following
FUJIK Silicone Thermal Glue - White (50ml Grease-Like) $6.28 on DX
5g Thermal Pads Conductive Heatsink Plaster Viscous Adhesive Glue for Chip VGA RAM LED IC Cooler Radiator - 3PCS white $2.25 on DX
MG Chemicals 832HD Black 1:1 Epoxy Encapsulating and Potting Compound, 25 milliliters Dual Dispenser $8.95 on Amazon
MG Chemicals 8329TCS Thermal Conductive Adhesive, Slow Cure, 15 g, 2 Dispeners $14.43 on Amazon

I also found MG Chemicals Thermally Conductive Epoxy Encapsulating and Potting Compound, 15 oz Kit, Black for $43.95 on Amazon (832TC), but it seems to be more bulk packaging…

2

I’ve used for a few yrs now.
Selleys (AUST) Ceramic 2 pot Epoxy in a combination delivery tube kit.
Nowadays it comes in several colours and pretty malleable,
thickened with talc.

I started using it’s forbearer yrs ago,
for bedding military rifle actions to custom stocks, to improve accuracy.
Mainly .303, 30-06. and 300WM. (Buff rifles) so plenty of “bump”.
None ever gave a problem.

Try it.
Just add Talc to thicken it. or it runs and flattens out over full board.
I practiced by cutting up a coupla matches into 1\4 in pieces and sticking to cardboard.
When it has enough filler. it don’t flow too much.
but needs more talc than you think.

3

Actually, if you’re potting components, the thinner the better. Gets into all the nooks and crannies between components fixes ’em in place but good. All the better if the ook wets to the components vs balling up.

Oh yeh, and to protect against shock (eg, if using it as a WML), you don’t want flexible material like RTV or anything. You want something like tough epoxy-resin that hardens into a rock.