PilotPTK 3 XM-L Module-Build Log

Flashlight Modding and DIY Parts
1

Note: This is not a finished project and what is seen in the below post may not be up to date. The way I do my projects is make something functional and then continually improve it.

I am installing it in a 3d maglite modified to run off of 3 18650 batteries.

First remove the switch using a 5/64 hex wrench.

Note: not my picture. I forgot to take a picture.

Using a hacksaw cut along the blue line.

Here a picture of the rest of the switch is.

Re-install it in the maglite. Then realize you need to solder wires to it and heat up your soldering iron and solder some wire to it.

One wire gets soldered to the center and the other to the wire that is already there.

Now we need to modify it so 3 18650 batteries will fit.

First remove the tailcap and take out the spare bulb and the spring. You will not need these.

I then cut a piece of 1 inch pvc pipe to the correct length so it fits into the tube. Then wrap it with electrical tape until it is a tight fit in the tube.

Here all the parts are layed out. I will talk about the heatsink later.

Then you need two small springs. I got these at my local ace hardware. These are in the above picture. I then took a small magnet and attached it to the top battery on the negative end.

Edit: The magnet was replaced by solder on the negative terminal of the battery.

You also need to take a drill bit and remove the anodization on the inside of the tailcap. Screw down the tailcap and you are done.

For the heatsink I decided to attempt to make my own similar to how OL does it. I went to the hardware store to look for copper fittings. They had 2 that were fairly close but that was all. I got a length of aluminum rod.

First, I placed the first copper fitting in the other and then filled the gap with other fittings I chopped up and some solder. I then cut the aluminum to the right length and stuck them in there. I just filled all of the space with aluminum.

Edit: I filled all of the gaps in this with solder.

Edit: I followed kramers advice and made a second one out of copper fittings I cut up and solder.

Then place it into the maglite and fill the gap between the body and the heatsink with aluminum sheet.

Here the completed maglite is hooked up to my dmm to check that it works.

Now I just need the module and then I will install it. :)

To be continued...

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Reserved.

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71 reads and no comments.

4

Why didn't you filled rest of heatsink with solder? :P

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I did I just forgot to take a picture of it. Or do you mean instead of aluminum? If so conductivity of lead=35.3 W m-1 K-1 Tin=66.8 W m-1 K-1 and aluminum=237 W m-1 K-1. Aluminum will conduct heat much better.

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Nono, I meant the empty space between pieces of copper and aluminium, would suck to have air there :Р

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8

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The one shown on 1st pic. :Р

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I did. I just forgot to take a picture before I installed it.

11

Ah, I see.

Are you getting NW or CW module, btw?

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CW with SS optics. :)

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These are specifications. (Cut and Pasted from an email) Explanation in italics.

No mode memory
6 modes
9.333V Low Voltage Cutoff-3.1 volts per cell cut off
100 Max Low Voltage Brightness
45C Over Temp Threshold-At this point it will decrease the brightness so as to keep the light cool .
Mode 1: Instant to brightness 1 (moonlight)-As dim as it goes
Mode 2: Infinite Adjust-This ramps from moonlight to maximum. When I click the button it will hold that brightness.
Mode 3: Infinite Lock-See above.
Mode 4: Instant to brightness 1 (moonlight)-As dim as it goes
Mode 5: Instant to brightness 500 (about half)
Mode 6: SOS-In morse code. -500 ms for dot and 1500 ms for dash.


The great thing about purchasing this is you get to program your own module with whatever modes you want. It doesn't require a knowledge of programming. :)
14

That heatsink is a bit messy job, don't like it...

15

It's true. It isn't perfect but being the impatient person I am I didn't want to wait a month to do this project.

16

Why did you remove the tailcap spring just to add two springs between the cells and one (round?!) magnet?

Heatsink truly is a hack job.

Your name is scaru.

I dont like you.

Thats about all.

:P

Good job so far, I've got two bigger Mags which I didnt mod yet because its just.. I dont want to. There are better hosts to mod. But keeps us updated!

17

The maglite spring is to big so 3 18650s wouldn't fit. The magnet has been replaced with a solder ball already and in the future the plan is to find a way to attach the a smaller spring to the maglite tailcap but I can't solder to aluminum.

18

I would remove the Aluminum. Looks like you have some thin sheet brass in there as well, remove that as well. Brass is a terrible thermal conductor. (compared to Aluminum and copper). Aluminum is a good conductor, but it won't adhere to solder so for the purpose of this design it should be removed.

Just fill the copper cap with as much copper layers/pieces as possible, inter mix it with a little solder like you have and heat it up on the stove. Solder generally melts around 275-300F, and can easily be heated to a melting point on your electric stove burner. Just heat it up and let the solder flow between all the layered copper pieces. Solder does have some thermal conductive properties, so its not a pure insulator (like air). IRC thermal conductivity of Solder is in the vicinity of titanium and brass (which are common materials with high $$$ builders). Let it cool down and you'll have a much better heatsink with no air gaps. The more copper mass you can add the better.

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Ok, I'll give that a shot. Be back in a bit with results.

20

Use sand paper to remove the ano from the inside of the tailcap. You can then work the stock spring into the cap all the way down with a little force & patience. It's a perfect fit for 3*18650.

Redo your heatsink to fit the tube snugly without the wires along the side. You can file grooves in the side for the wire or just drill holes for the wires to pass through. Right now your heatsink only touches in one spot really and is pretty much useless. I would also suggest you edit the first post and add that you filled the empty space with solder so people don't think you left it like the picture and accuse you of being a hack. ;)

Looking forward to seeing Pilot's array in action! :)