COURUI Conversion: Parallel to Series ~ "My Way" ~~~ Heat Sink Finished ~~~. Mod Finished ..."Really Finished"!!!

The tailcap is finished! Modding details and photos added to the OP.

Very nice work on the tailcap switch and conversion, I’ve been tempted to do something similar but just for the easy lockout possibility while keep the battery configuration and side clicky. I’ve blinded myself too many times to count getting used to that sensitive side clicky! :wink:

I’m not an expert when it comes to machining but I had a similar task on my BTU and couldn’t risk drilling off center. I used something like this ” conical drill bit”:Shop by Category | eBay

Even using a hand drill I managed to get a nice and centered hole perfectly round with much less wandering than if I had used a similarly sized normal drill bit. Might be worth considering next time.

Is there really no driver option available that supports the side switch?
Seems such a shame to bypass one of the great features of this light just to get regulated output

Just saw your other thread, you’re using the ld-36 driver?

Thanks Linus.
I’ve been looking for a 3x18650 soupcan for a while just to see if my idea for a series conversion would work. I also have scads of 4P lights, and needed the change.

I plan to install a 7A buck driver for no other reason than I’ve never run a single XM-L2 over 5A before. I don’t know what will happen. It seems like a waste of space just having a single board driver in that big cavity.

I’m in the middle of redesigning the heat sinking on the pill. I’ll be posting the build and photos in the OP.

I did order an LD-36 driver. I also ordered another COURUI (in case I wrecked this one), so it may go in that one. I’d install another tail switch just for easy lockout.

Thanks for the bit link. I’ll be seriously looking at them. I guess you have to keep stopping the drill to take measurements. I also took notice of that reflector you installed in your COURUI and ordered a couple.

Yeah I actually had one without the stepping so I just drilled until I got to the right size, the steps should be known diameters so that should actually be easier. I think what helps is the cuts are gradual and the previous step acts as a centering hole for the next cut. They’re also perfectly round except for where the cutting edge is recessed so I’m sure that also helps avoid wandering compared to helical drills.

You mean the acrylic lens right? I’m still really impressed with mine so hopefully you will be too, no scratches yet either ! :slight_smile:

i wish mine will get here all ready its been over 4+ weeks from KD, if i go this route like Ouchyfoot did i will not use the rubber boot, ill have a little piece of aluminum machined to fit the hole ?

Very cool, I’ll keep that in mind when I get my driver in.

Ouchyfoot do u mind if i post a pic or 2 of my switch ?

Knock yourself out Nitro.

PS: I got my second COURUI. Eight days from day of mailing. My first one came real fast also.

true luck there it took one of mine 41/2 weeks and still waiting on my other

judco switch :slight_smile: 10 amps >)
!!

how thick the button it
!!

and how far it sticks out as shown on the right
!!

Also im going to the harware store and im getting a stainless steel washer and im going to place it around the click switch to cover up the little hole showing

Impressive work Ouchy!

Looks like a great mod!

Ill be following this thread.

:beer:

Nitro. How far does the switch extend inside the head? Do you have a link for the Judco?

its about 10-13mm from the inside but this is what im going to do for my heatsink

the heatsink will slide in and it will keep my switch cool as well, and it will be set in place by a set screw
!!

and i used this

http://www.digikey.com/catalog/en/partgroup/j-188-series/17706

That looks like it will be a pretty thick slug. How much room will be left for the driver?

that im not there yet but by the looks of it i should have around 12-15mm of space, but im working on a driver i might use :slight_smile: sorry no pics/info on that yet :wink:

EDIT: my copper slug will be 34mm wide and around the same long and will be machined at the end for the driver

the battery connector is like :open_mouth:

Great creative thinking and work there Ouchy. I'm bookmarking this thread.

The mod is “Finished”!
Complete photos added to the Original Post

too bad the battery tube split in two :_(

dang that sucks, if u want to get rid of the broke host send me a pm ?