Cheapo AA Flashlight Mod

Flashlight Modding and DIY Parts
21

Hi MascaratumB, I’m sure you’re getting excited to start your mod.

For the switch, I only used the plastic holder. With the bigger switch in the holder, I had to press very hard press to get it into the tail, but that also helps keep it in place.

Yes, soldering a wire from the tab to the top of the spring will be a spring bypass, but only 1 tab should touch the side of the flashlight else it will always be on essentially bypassing the switch.

I used the insulation gasket when I got the aluminum reflector. The cheapo flashlight came with a smooth plastic reflector so it didn’t need the gasket. The gasket helps prevent a short across the LED. The rings came from the original plastic reflector which was designed to work with the original LED. I tried experimenting with the plastic reflector height here: Mod Advice For a Cheapo Flashlight, but wasn’t too successful.

22

Chuckle. Now you can replace the battery tube to use a bigger cell ….

“This is my grandfather’s axe. My father replaced the handle. I replaced the head. But it’s still my grandfather’s axe …”

Good thread well illustrated. This is what it’s all about.

23

Very nice, thanks for sharing !

Which driver did you use ? I suppose you wanted to stay with eneloops, not Li-Ion 14500, correct ? Boost driver are not easy to find these days … :frowning:

24

Thanks for your answers NeutralFan!
Yeah, I’m getting excited with my first mod. Actually, I guess I’ll be doing 2 mods in a row! I’ll post them after they’re done :wink:

Hum, I guess I’ll have to add someting on the switch to get it tighter!
I also had to sand it a bit, like you did, and now it is a bit loose. Maybe a plastic ring above it! Would a metal ring (that might get in contact with the battery bottom) be better or worse?

Thanks for the info about the bypass! I guess I won’t have to make it because everything seems to be in the right place, so far! :+1:

So, about the gasket, it’s not only about reflection but also the short that may happen! Nice to know, I want it to be safe to use and not to damage the emitter or LED or whatever may get damage :wink:

I’ve looked at my order and I ordered insulation gasktes so I may rest… for now!
And yeah, that first “mod” in the reflector wasn’t that good! Thanks for the warning, it might be a thing I’d do just to get things fit!

We learn from each others good and bad experiences, that’s what I like here on BLF!

Once again, thanks for sharing!!! Nice work!! :+1:

25

Here’s the driver I got from Mountain Electronics: Lumintop Single Board. That is correct, I wanted to keep it an AA flashlight.

26

As long as the metal ring does not come in contact with the spring or the negative terminal of the battery, you should be fine else again you would be bypassing the switch. Seems it would be safer to use a plastic ring.

27

Hum, I guess it might be in contact with both (spring and battery)! I’ll add a plastic ring instead, it will be safer.
Thanks for the information once again! :+1:

Best regards!