3D Maglite. Tenergy NiMh. One Two 2800mA Flex Asgard drivers. XML2 U2 '1C'. Copper pipe. 8-10 hours at the drill press to turn an old CPU heatsink into a pill. A little blood and lots of foul language and throwing things.
Will it work after final assembly? Who knows. (that's the stage where the first driver decided to stop working for no reason) :sick:
So you bought two Flex Asgards in order to get two of its driver?
No, just two bare drivers.
FT sells bare driver?
nice! i was wondering when we would start to see these installed in other hosts.
that’s some seriously impressive work just using a drill press as a mill and well done for your perseverance/ stubbornness with the driver 
I hope that loss of blood didn’t = loss of fingers!
The 'pill' started out as this (yes, this is the kind of thing you end up doing when you're both cheap and too lazy to search out the cheapest option for raw bar stock):
I like this already 
You could try 1 3/8 aluminum round bar. A D size Maglite ID on the tube should measure about 1.348”.
1 3/8 bar should measure 1.375”, .027” difference. That’s less than a 1/64 of a inch off the sides or 1/32 in diameter, very doable.
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This is my source for aluminum stock. The cheapest on aluminum stock I have found. $6.18 per a foot.
http://www.stockcarsteel.com/aluminum-round-bar/6061-aluminum-round-bar
They sent me a coupon code for this month 15% off code: ERIKJONESWIN expires 9-1-13. Its been awhile since I have ordered anything. If you call them, I have been told they can offer cheaper shipping options.
Yessir, just this AM I finally hit the 'checkout' button on this (http://www.ebay.com/itm/360667109846) after having it in my cart for over a month.
Bluetooth works even with the head on & fully assembled with a plastic Mag LED reflector & plastic lens. The light seems ok, but the Android app occasionally locks up after loading a new profile to the light and then manually switching modes from within the app... annoying. I hope they haven't given up on the FLEXcandles project, cause it's still not quite up to snuff.
damn, that’s a lot of aluminium rod. I’m still seriously impressed at how neatly you turned that heatsink down with a drill press, I honestly would have assumed it was done a lathe unless you mentioned otherwise.
Damn nice work.
I usually have Speedy Metals cut my bar stock to the lengths I want. I ask for exact lengths and they do not charge extra. I usually work it to where the shipping price is best per piece, so on smaller stock, it might be 12 pieces and on larger, it might be 3 pieces.
I like it! Maglite + Asgard driver= COOL!
I planned on doing Maglite + Asgard myself, assuming I was happy with my first one, but my driver still needs a repair. So Im not tempted to buy a 2nd driver. Maybe Ill end up mending the one I got with a hammer. Time will tell.
I noticed FT does not have any Asgard flashlights in stock, I wonder if there is a reason.. Something to do with the driver?
When that is said, I doubt I would have made such a nice Maglite as you did. Seems like one really nice light you have put together!
What is the grey wire with the green thing on it.
bt antenna
Nice build comfychair. You effort is to be commended. I must find out where to get it one day. Patience that is.
The OD of the pill was actually done on the wheel of my bench belt sander, wasn't my intention but it came out smaller than I wanted from that step and just got lucky that I didn't cut too much off, and it somehow came out being both round and just the right size that you can't quite remove it without a little work with some skinny pliers.
All the steps and other cuts on the driver compartment were done with the end mills, using a homemade guide fence clamped in the vise so the part could be spun in a concentric circle while cutting. Just making shallow cuts and sneaking up on the final dimensions. You can't really see in any of the pics but there are two pockets cut in the roof of the driver compartment to clear the 3-leg transistor and a diode, so it only fits in there one way. Getting the +/- jumper wires between the contact plate & driver just the right length and position so the two boards were both oriented correctly when stacked AND able to lay flat enough was maybe the trickiest most annoying part of the whole thing.
I guess now I need to pick up a new host of the correct color for it, I mean it doesn't seem right to have a red bluetooth light, does it?