Well, I said I had some inexpensive lights to play around with. This one isn't one of them.
This 2AA will end up being a 3AA, with a tail switch and an XR-E on a heatsink.
It staretd out with an incan 2AA and some copper fittings/pipe. I decided to go 3AA because I wanted to work on the "Human Lathe" technique. I need to use that on my cut down 2D, so I'm practicing here.
I am using a Dremel tool in my variable speed drill. I also have tried the stone, but stones and aluminum do not work.
Both pieces are now cut for the copper pipe. The pipe is 1/2" type "M". Type "L" will not work, as the batteries will not go in. Type "M" is a much thinner wall.
The pipe is the inner piece that fits into both ends of the light body. The 1/2" unions are the outer piece and I solder them together and to the inner pipe, to make a strong insert.
I think I will leave it with the "brushed look".
I also decided to use a tail switch, so I could have some room for a small heat sink in the top of the body tube. Chicago X had sent me a couple of switches to play with. I think the one I massacred was a Rominsen? Not sure about it, but it had an all aluminum body/threads, so I cut off all the threads and smoothed it down, then I bored out the Maglite tailcap.
I will be adhering the switch into the cap with a two part epoxy bond, that is like a putty in a tube. That stuff hardens really well and I can sand and trim on it. It's similar to JB Weld.
I still have to order emitters from one of the US sources, so this is another "WIP" job.
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Ok, I got some time to work more on this light. I decided that the all copper center section did not look good at all, but I found a way to make it look better and more unique.
I sprayed just the copper with Krylon Crystal clear Acrylic. Then I cut a piece of painters masking tape into thin strips and put them on the copper. I did it by eye without measuring anything. After that I painted the whole thing with Rustoleum Textured Metallic and removed the tape. The final coat was another coat of Krylon.
Here's some close-up shots.
I really like this textured finish, with the copper flake in it.
I also worked on the heat sink a little. Here's some photos.
It's a 3/8" copper end cap, with a 1/4" copper end cap inside and the rest is solder.
It still needs finishing work, but you can get the idea.
The positive terminal will be isolated from the heat sink with a plastic washer and the brass washer will be the contact, with the wire soldered to it.
The heat sink will be pressed into the barrel and will be flush, with the emitter sitting on top.
That's all for now...
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