Hi people I have just discovered the art of torch (flashlight) modding and this is my first patient, I went down to the local “junk yard” and found a collection of preloved torches that use a cordless battery 18 volt to power it. Yes i hear everyone say thats no good. But I have modded the battery packs!
This being my first one I was not expecting to much but after completing it seems to be pretty good.
Presenting John Doe
John Doe in pieces, the head did need some drastic internal reconstruction. (not shown as it may offend some viewers) LOL
Here we have the LED XML T6 mounted on the heat sink (heat sink donated by PC found on the side of the road)
Showing the heat sink and reflector being tested. I used 5min araldite to stick reflector to the heat sink but that failed after the first 2 days.
Alternative reflector to heat sink attachment. I drilled 2 holes for 3mm self tapping screws, sanded the zinc coating off and tinned the outer rim. I was amazed that it actually stuck. I counter sunk the heat sink so the head of the screw was flush with the surface. I got the reflector which was steel and added solder to the edge and to my surprise it stuck. I then placed them together and used a small butane torch to melt them together and viola Like poo to the proverbial blanket.
The battery was 15 Nicads that were still in working order so they were salvaged and reused. I put 3 X 1300m amp paralleled and 3 sets in serias.
It has worked a treat, very functional and lasts a really long time ( have used it for 2.5hours and still on the first charge) The original globe lasted 15 odd mins.
Nice mod DJK. It was not that long ago that GMC sponsored our greatest race before they went bust. Have you any night shots coming up? Welcome to the forum also. Cheers.
Thanks MRsDNF
Night shots are near impossible with my mobile phone camera. The othe half has our “good” camera taking pics of our two day old son, when I get a hold of it and have some time I will post some. It has a nice wide flood no real spot to speak of but for when you are in a roof cavity of the like its fantastic.
This is nice, but how do you re-charge the batteries, You now have a 3.6V pack. I know Ni-Cads get a bum wrap, but they are actually quite good. Of all the cell technologies they probably are the least sensitive to misuse.
I have a number of these type of lights that I have accumulated over the years that have blown bulbs. I have refused throwing them out, and have them in a pile. I will have to try modding one.
I have salvaged a battery clip from non working cordless drill and added leads and an XT60 plug. I use a converted PC power supply to power a Turnigy accucell 6amp charger Turnigy Accucel-6
Cool mod! I have a brand new never used light like this. Would be nice to get a driver that could go up to the 19.2v (perhaps a bit higher) and have the battery recharged by the original charger. Thanks for sharing! Oh, & welcome to BLF!
I’d be careful about charging the NiCds like that though, as the paralleled cells will obscured the dV signal used for charge termination on most chargers. If you can, charge it at a low rate (1/10C, so probably 100-200mA at most) using a timer. That way you’ll avoid overcharging it which will knacker the cells.
Given that it looks like you’re fine with soldering cells, it would be worth looking for some old laptop packs to scavenge 18650 cells from. If you don’t have any luck, I have a bag of cells that I could dig a few out of for you (edit: nuts, noticed that you’re in Oz)
Note to self remember to have only one LED or driver out of the original bag at once as identification is very hard with some of the items with no identifying marks, dont ask how I know!!! :_(
