A few odds and sods. Successfully rolled and brazed .25mm sheet brass into an 18650 tube for woodifying the thinner 18650 host tubes that are only ~20mm OD at the o-ring lands(S2+, X6, E2L, etc). Also a few coats of epoxy on a mahogany tube and filled a custom copper C8 spacer with an aluminum slug tapped so it can be screwed to the stock pill(old style).
Today, I finally did a mod where I could use a Khatod quad optic, which is quite a bit taller than the Carclo.
Astrolux K01.
Removed the reflector and single MCPCB (which, oddly, was a 16mm DTP copper, even though the cavity can take a 20mm) and measured it against the T-pad/Khatod and found I would need about a 5mm spacer. I had an S2+ copper spacer from Mtn, but it was closer to 10mm. I managed to grind and file it down to an appropriate thickness.it slid in nice and snug with a little Antec 7 diamond thermal compound… I had to grind the bottom half of the legs on the optic to match the MCPCB, which didn’t leave much material, but enough, to fit in to the pill.
For now, I just reused the stock driver and wires.
I am extremely pleased with the result! The only T-pad I had already populated had some XP-G3 S5 3A. These optics are, as I had hoped, way more narrow than a 10507 Carclo. It is almost as narrow as the stock reflector, but has 4 LED’s feeding the spot!
I can’t wait to check it out in the dark!
I’ll probably swap the driver out eventually for something with active thermal management and do a spring bypass in the tail, but I’m real happy with the way it turned out!
A teaser for a scratch-build I’m planning. It will be a 7x C8 reflector light with dedomed XPL emitters. 125mm diameter head. 2s 26650; the same electrical setup as my 7xXPL convoy L2. The drawing is actual size, with a convoy C8 for scale.
A drawing of the head, with my 7xXPL L2 for scale.
Should do around 9000 lumens OTF and 800+ Kcd. Made from “off the shelf” aluminum plate and tubing.
That will be one heck of a flashlight EasyB! Looking forward to it.
Thats scary EasyB. :+1:
After my UF1504 only put out around 200kcd I figured the bottle neck was that dang half inch long solid brass button resting on the tailcap spring. I don’t understand why brass buttons are used. I always have to drill through them. Drilled a hold down the middle and ran a bypass wire up through. Hoping that will at least double the throw numbers. Haven’t taken measurements yet.
On the road i3. Dedomed dtp xpg2, Fet driver, omten switch and double springs.
Real nice little light, joy to mod. Still don’t know if I keep it like this or put a 4000k 219c in it.
Tint vs throw, that’s the question…
Dedome a 5000K 219C. You end up with about 4000K, lots of throw and nicer tint than most dedomed Crees.
I have some 4000k’s laying around. Guess I’ll try to dedome those first.
Is slicing the dome still the way to go? Or is there a new proofed method for 219c’s?
Maglite 2AA - Triple mini mag mod
Bored out the head using a 19,5mm drill :
Modded a threaded copper pill from Rey Ti , added a 16mm round copper plate to make the flat surface on top , all using only hand tools , and installed a fet driver and nichia 219b hi cri leds on KD board and optics :
Added some solder on the bottom , now even flat top batteries work :
And inside the head :
About the tube , i shortened it using the human lathe method kyfishguy described :
It could be better of course 
.
Changed tailcap’s spring to a bigger and more flexible one :
Khaki painting was in pretty bad shaped , so i removed it from the areas without knurling .
And final product :
Thanks to kyfishguy for helping me , and Lexel for providing the light .
I guess that modding Maglites will never cease, it is sort of tradition on BLF to do them. I will do mine one day!
Nice mod, giorgoskok!
Buying an led conversion for a 2AA mag was the first mod I ever did. That’s where it started for me 
nice mod giorgoskok
Thanks for your kind words It wasn’t an easy mod since i have no lathe , but worth every minute . :heart_eyes:
Hey George,
It’s great to see you’ve finally completed your triple micro mag. It looks great and I bet it puts out a pretty wall of light! That seam on the battery tube actually looks pretty good, did it take much adjusting to function smoothly or was it one of those rare ones that goes back together great on the first try?
Brian
Thanks Brian .
The battery tube came pretty good , i was modifying it and testing it back again for 2-3 times until i get a good fit , without creating much resistance .
Love the mod George and good to see Justins traditions being carried on. I’ve said this before and will more than likely say it again, The AA Maglite would have to be one of the best looking lights on the market.
Very nice giorgoskok! I like the way it turned out. Was it hard to bore out the head?
Thanks guys! It was the easiest part for me , making the pill was the challenge !
I modded a ThorFire TG06S…Nichia 219C and a fet+1 w/ bistro. The mcpcb was around 15.2mm…all I had was a 20mm so I sanded it down to fit. There was no need to sand the 17mm driver as it fit perfectly. I also drilled a hole in the switch and ran a wire from the spring to the switch leg. I added a little resistance by using 24awg wire so I don’t end up smoking the led. ThorFire did good by going with a reverse clicky in the TG06S instead of a forward clicky like the previous model. Here’s a couple of pics…
Modded TG06S left…stock TG06S right
No PWM from fet…lots of PWM from stock driver
To bore a Minimag I start with a step drill to keep it well centered then finish with a hole saw to get a flat bottom shelf. The rough cut from that is then reamed with a sandpaper wrapped bit. The head is first wrapped in tape then pressed into a 1”hole in a 1 x 4 wood block clamped to the bench press table.