RaceR`s 3xAA P60 host. Price, 8.75$

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RaceR86
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RaceR`s 3xAA P60 host. Price, 8.75$

This is a very quick and simple mod if you have access to a lathe.

I started out with a Small ZUN ZY-123. Bought from manafont to the price of 8.75$

It was really crappy. Which was good, because I had plans for this light.

I modified the P60 reflector.

Its the one on the left side, as you can see, I had to take off quite a bit. So more spill, and a bit less bright hotspot.

Then I took away some paint on the flashlight body for good contact with the P60.

Put the P60 inside the light. And voila. Done!

Compared with other P60 lights.

Do not buy the Small Sun – ZY-B4 for this type of mod. The head is not that good suited. Small opening even though the head have a decent size. And the button will melt. I speak from experience.
The ZY-123 have worked perfectly, and its really comfortable to hold.
Nice, quick and simple mod if you have the tools for the job.

If you are interested in that shiny P60 light. Build thread here.
Thanks for reading.

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Edited by: RaceR86 on 03/26/2013 - 15:22
benz
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Looks good! What was so bad about the original emitter/reflector?

RaceR86
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benz wrote:
Looks good! What was so bad about the original emitter/reflector?

Thanks
Original emitter: Not sure what it was. Some cheapo led im not familiar with. Tint was probably 7000k, if not closer to 7300-7500k. Way to blue for my taste.
Driver: next mode memory :Sp Never bothered measuring the tailcap. Light output was not impressive by my standards.
Reflector: Plastic
Pill/heatsinking: Press-in 20mm driver board, and a press in 20mm star. No thermal paste or anything. Not like that would have made a difference.
The pill was only 5mm thick . And it was basically completely hollow! A 18,5mm star would fall straight through it!

A nice P60 was a huge upgrade in this light! Smile

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relic38
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Nice mod RaceR!
For those without a lathe, it would take a lot of grinding to bring the P60 reflector down to size. A bench grinder would help.
Good to know about this anyway. Thanks for sharing!

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RaceR86
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Thanks relic.
yeah, I would never consider grinding that much of the reflector. At some point, it would probably get damaged too.
But for those with access to a lathe. The job is so easy that even a monkey could do it. (I suck, but it was super easy)

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Thanks for the idea RaceR86! I got this POLICE 8W from Banggood ($7.29) and it looks the same. Ignored for a long time for the reasons you have mentioned earlier.

I did a preliminary measurement and looks like it will work. Hard part is cutting the reflector without a lathe!

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Good Mod! Maybe the old "hand lathe" might work.

Scary thought...

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Just did it a while ago:









I like it! You can use any P60 pill by just swapping the reflector for this light.
Tried it on my XP-G2, XM-L, XM-L2.
Works on 3xAA, 3xNimh and 1× 14500 with 2x Blanks.

Recommended to those looking for XML using 3xAA. Beer

RaceR86
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Thanks for sharing your work. And welcome to the very exclusive Triple AA Modified P60 Club! Wink

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Racer, I’ve had this bookmarked for months because I thought that if I was every inspired enough I could try it by hand. Now that Tivo has actually done it, I really feel like I can too. You guys have really inspired me. Thanks.

BTW, Racer, where did that red Ultrafire come from? That tail cap is pretty unusual, no?

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I found a $6.89 from eBay.

RaceR86
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cone wrote:
Racer, I’ve had this bookmarked for months because I thought that if I was every inspired enough I could try it by hand. Now that Tivo has actually done it, I really feel like I can too. You guys have really inspired me. Thanks.

BTW, Racer, where did that red Ultrafire come from? That tail cap is pretty unusual, no?

That is nice to hear. Smile

The red 502B came from here.
Is the tail cap unusual for that light? I have no idea, I just wanted a red light that was not another 501
Smile

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RaceR86 wrote:

That is nice to hear. Smile

The red 502B came from here.
Is the tail cap unusual for that light? I have no idea, I just wanted a red light that was not another 501
Smile

I’ve made no secret of the fact that I am more of a user/hoarder than a modder/flashaholic, but I have really like P60 lights and it would be neat to have one that used AAs. I am totally going to try this.

As for that tail cap, all of my Ultrafire hosts look like the two on the right side of your pick. That radiused tail cap really caught my eye.

Btw, how was LED SuperMall to buy from? Any issues?

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RaceR86
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cone wrote:

I’ve made no secret of the fact that I am more of a user/hoarder than a modder/flashaholic, but I have really like P60 lights and it would be neat to have one that used AAs. I am totally going to try this.

As for that tail cap, all of my Ultrafire hosts look like the two on the right side of your pick. That radiused tail cap really caught my eye.

Btw, how was LED SuperMall to buy from? Any issues?

Good luck in your attempt. Worst thing that could happen is that you ruin a cheap reflector.
If you are not aware, by making the reflector slightly shorter and thinner you will increase “the spill ring”, and decrease throw a little.

My package from that store arrived after 12 days, so hopefully shipping is normally fast (or maybe I was just lucky). No issues or complaints from me, but then again, I have only used them once and have not been in need of support.

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RaceR86 wrote:
Good luck in your attempt. Worst thing that could happen is that you ruin a cheap reflector.

Not too worried about that. I sometimes buy hosts with 18650 drop ins in them because I can’t find the same empty host anywhere. Since I run primaries, these drop ins just sit around taking up space. But they will totally work in a three AA setup, so I can bugger up a couple and I won’t really be out anything.

I’m mechanically inclined, so I’m pretty sure I can do it. Glasses

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RaceR86
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I see what you are saying. Colored 501Bs are usually fairly easy to find empty for a fairly low price.
I don’t think that was the case with the colored 502s.

Feel free to keep us updated on how the mod goes.. Smile

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The lens on my POLICE 8W is 23mm. Know of any vendor for 23mm glass lens? Beer

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Hey RaceR,

After reading your post a few months ago I bookmarked the Manafont link, I figured this would be a great P60 based light for friends without worrying about Li-Ion education. I ordered a couple of them a few weeks ago and just got them today.

I’m going to go with an XM-L P60 in one but after looking at the light I have other ideas for the second one.

I’m curious though about how many amps the switch can take, what is your drop-in drawing?

Nice find,
Matt

Edit:
Done, installed an Int’l Outdoor 3 mode neutral XM-L drop-in. I liked the Int’l Outdoor reflector so I cut down a spare smo reflector. After all the fitting was done the beam was somewhat crappy so I ended up stippling it, added a gid O-ring between the reflector and lens just for giggles. As expected, the beam is all flood but nice and bright, I’m getting just under 3.0A with eneloops.

Don’t know how long it will survive at 3A, I just ran it on High and just after the 5 min point the light dimmed down. Turned off and waited about 2 minutes and all seems fine. I don’t know if this drop-in has thermal protection but the switch still feels fine. There’s little thermal path but the whole body of the light was hot.

A few notes on the host, it has O-rings for the head and tail cap but they’re so thin I don’t think they touch anything but the body. The body however is built like a brick, the walls are thick enough that you could probably drive a car over it without damage. Then again there’s the threads on that body, screwing on either the head or tail cap was like fingernails on a chalkboard. No problem with cross-threading but just not something you’d want to do often.
A thorough cleaning and lubing resulted in very clean, well lubed crappy threads. Oh well, it’s cheap host.

All in all it took me about a half hour to make this into a nice little light for gifting to non-flashaholics.

And a quick teaser for my plans for the second one, I have a few spare heatsinks like this kicking around, just need to decide/order the LEDs.

Again, all credit to RaceR

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RaceR86
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I used a 3 amp drop-in. Never had it on high for more than 7 or so minutes of continuous use.  Did not have any issues. The button is fairly similar to one of the Omten 1,5A switches being sold from FT. If stock switch should say "bye, bye, Ive had it". There are replacement options that could be fitted or be made to fit.

Stock tailcap spring looks quite crappy, so copper braid mod would not be a dumb idea btw.

Right now, I mainly have it as a back-up light. I don't use my P60s that much. And I prefer the complete P60 reflector to this cut one. (The one in my bling AA light is good though, barely cut anything off it). I just like having the ability to put whatever I want in a 3xAA light. Smile

Edit: Btw, nice drop-ins! Wink drool....

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If cutting down the reflector is a bit fiddly, how much easier or harder would it be to fit a TIR in this light? 

Never done it, just curious as to whether it would be a viable option.  Or would it be too fiddly making spacers, etc? 

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If you have accsess to a lathe, cutting down reflector is the worlds easiest thing.

My cut reflector is roughly 18,5mm deep (including threads) and 22,7mm wide. 

Im not aware of any TIR optics in that size. The typical TIR optics Im aware of are 20mm wide, and they would fall through the opening in the head.

Edit: Also the P60 reflector is the main thing transferring heat to the head when using a P60 pill. 

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OK,  thanks for that RaceR86

It's a bit hard to tell from pictures alone.  So the reflector is actually touching the material of the head just like in a P60 host then?  I sort of figured from the pictures in the OP that maybe some heat might be transferred via the spring but I wouldn't have figured it to be much. 

I was actually going to ask about heatsinking..... Interesting that you used a 3A dropin and got up to 7 mins on high.  Did you ever do a tailcap test to see if it was actually drawing this much as it seems a lot of heat for such a small host?

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I owe you guys an apology. I kept walking past this thread without dropping in. Being the quiet night it is I dropped in. I’m glad I did. Its full off modified lights. I like em all thanks guys. It still amazes me what you all turn out with what you have at hand. Its very inspirational. Cheers.

 

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gadabout wrote:

OK,  thanks for that RaceR86

It's a bit hard to tell from pictures alone.  So the reflector is actually touching the material of the head just like in a P60 host then?  I sort of figured from the pictures in the OP that maybe some heat might be transferred via the spring but I wouldn't have figured it to be much. 

I was actually going to ask about heatsinking..... Interesting that you used a 3A dropin and got up to 7 mins on high.  Did you ever do a tailcap test to see if it was actually drawing this much as it seems a lot of heat for such a small host?

 

Its only the top of the head that is properly touching the body. If i were concerned about heat I would just wrap it.

No, I did not measure the tailcap after 7 minutes, but (first gen) XM-L + 3 good AA seems to hold fairly high current. In that light, I could not care if output is not perfectly regulated at a constant 3 amps..

I have not used the light lately, I just have it standing ready if I want to put one of my various P60s in it. Its nice having the option of putting whatever I want in a 3AA light, weather it should be a multi-color led, UV-led (soon to be made), a Nichia on copper pushing max output (2A+), or a more regular drop-in... 

Actually, my cousin just recently just saw my multi-color drop-in in action and wanted it. Police strobe is cool! Wink  So I just took it out the the host, put it in a super cheap black 501B that I had laying around, and then I had a fairly cheap light ready for him at no time. If he was not familiar with li-ion and electronics, I could have just given him the 3xAA light instead. Its nice having options. That is the beauty of P60s. Easy customization on the spot. Having various hosts with various battery types just adds to it.

When that is said, personally, Id take a nice and short 18650 with a a proper reflector 98% of the time.

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RaceR86 wrote:

 

I have not used the light lately, I just have it standing ready if I want to put one of my various P60s in it. Its nice having the option of putting whatever I want in a 3AA light, weather it should be a multi-color led, UV-led (soon to be made), a Nichia on copper pushing max output (2A+), or a more regular drop-in... 

Actually, my cousin just recently just saw my multi-color drop-in in action and wanted it. Police strobe is cool! Wink  So I just took it out the the host, put it in a super cheap black 501B that I had laying around, and then I had a fairly cheap light ready for him at no time. If he was not familiar with li-ion and electronics, I could have just given him the 3xAA light instead. Its nice having options. That is the beauty of P60s. Easy customization on the spot. Having various hosts with various battery types just adds to it.

Yep, the P60 format still has a lot of appeal as far as I'm concerned - for exactly the "mix and match" reasons you describe.  Thermal constraints mean it isn't the best choice for super-high output in the hands of the uninitiated but as a general purpose light, it's quite adequate.

I really like the 3AA option and your use of such an economical host makes it all that much more affordable.  Good light to hand out to kids for camping and running about.  I don't think this Manafont one will replace my 3AA Javelin, but for the price difference I might get a couple just to play with.

Thanks again for sharing.

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is the one in camouflage a wf501b? i’m looking for something like that for my little brother but don’t know if there’s any take take AA batteries, he’s crazy for camouflage stuff.

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Build thread here.

I remember a time, when I searched for lights to fit my needs. Now I search for needs to fit my lights.

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Nice, inventive on cutting the P-60 reflector, awesome!

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What an inspiring mod!
I see you hardly lost any reflector surface, and looks better than most P60 hosts i.m.o.

But this I also have to know:

That little silver one is so extremely attractive.
What is it and where did you get it?
It’s so pretty!

RaceR86
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Here you are Jerommel. Smile

http://budgetlightforum.com/node/20100

 (btw, it was linked to in OP)

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(yes, I see now. Missed that.. thanks)

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