Damascus Light Build for Matt Walker

Flashlight Modding and DIY Parts
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I know I'm a little slow getting this up, but machining Damascus steel is a bit different and took some extra time and concentration (for me anyway).

First, let me just say that this steel is gorgeous. I can't adequately explain it, but I REALLY dig the way it looks. Second, machining it is very different than cold rolled steel or aluminum or even copper. I found that I had to take a pretty deep cut at a high RPM to get a good surface finish. Even then, there is a little bit of imperfection to the finish but a small amount of polishing with 320 grit paper and a scotch brite makes it perfect.

I found myself really stuck for several hours figuring out whether to go with a reflector or an optic. I like reflectors much better than optics, but they occupy a lot more space in the head. I wanted to keep the light short. You see my conundrum. I ended up compromising and decided to cut the reflector that I had shorter. Next, I had to decide how I was going to drive the LED. I had already decided on a 14500 battery. I decided that this light is for Matt and he wanted a light to showcase his Damascus. So, I went with a Qlite with the normal three modes. I already had a UCLp from flashlightlens.com, so that was an easy choice. A McClicky rounded out the parts needed.

Of course, I had to add a little copper into the mix. I decided on a copper pill with just a small shoulder that would separate the head from the body. I like the idea of exposed copper as a contrast to the Damascus.

I measured everything and drew up a plan for each part. My notebook for this stuff is getting pretty full:)

Here is a pic of the Damascus before I started.


Center drilling the head.

Drilling the head


Threading the head for the pill.

Reaming the pocket for the driver.

Driver Pocket

Head and pill assembled.

Drilling the body


After the OD has been machined and polished.


Body sawed off for facing to length and drilling the other end.


Head and body together.

That's it for now. I work 2nd shift today and have some stuff going on tomorrow so probably no updates until Wednesday or Thursday.

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Its a beauty! :beer:

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This is golden. Thanks for sharing!!

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I forgot to add that the pattern will come out when it is etched.

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Wow, beautiful! Will you be using the standard 3A qlite? Also, what led are you using?

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Yes, standard 3 amp Qlite. This light is to showcase his steel, not how fast a battery can be drained (like most of my stuff). As far as LED, I am 90% decided on XM-L2. It's an EDC so I want a fairly wide beam profile.

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Fuuuhh… that’s a relief :smiley:

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What are you going to use for the etching solution? I suppose something not too harsh, is Matt going to give you input on what to use? Is he going to do the etching himself?

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I’m very jealous of your tools and skills… :frowning:
Please stop flaunting.

:wink:

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Matt told me what to buy. It should be delivered tomorrow. It's phosphoric acid if memory serves.

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I was thinking he was going to etch it himself since he probably knows more about steels, etching times, preping solutions before etching, etc.

Make sure you get that steel super clean from any oils, fingerprints etc, so it takes a good etch :slight_smile:

Pay close attention to time and make sure to completely neutralize the acid afterwards or it will keep etching itself for a while…

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Will do. I would cry if it was ruined at that stage.

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Sent you a PM…

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Another beautiful light!

Your cat, friend, is dead.

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Looking good Bucket. Now wheres Dale. I'm getting lonely watching this by myself and the ice is melted.

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It’ll be one sweet EDC!

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I just found this thread, Yeah, I’m smiling :slight_smile: :exmark:

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Can not wait for this to be done and see the pattern come out after the etch.

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Epic! Doing great work here, loving the interior details, can’t wait for exterior details…

<—-dumping ice and rock salt into the ice chest. Sorry, had to pick up some more brew.

So, are you going for an optimized mule set-up, by cutting down a reflector? Looking for a nice wide flood of light or what is your objective there? I almost want to recommend an XP-G2 S2 2B, with the Qlite pulled back to like 2.28A (2 chips removed) to give a nice output but keeping a long runtime. Engaging moon mode? I think it’d be cool on this light to be able to see the emitter giving off that soft glow, allowing the incredible Damascus to show while seeing the light is operational. Great for showing it off and handing it around. Also very versatile for EDC use. :wink: That would still allow in excess of 500 lumens or at least thereabouts so that it’d be impressive, semi-throwy, and an all around performer.

I could be totally wrong though. Been off kilter the last month or so.

Edit: Easy on these Aventino’s Steve, at around $6 ea and at a potent alcohol level they need to be savored, like this Damascus. :slight_smile: