Copper Attitude - Or, Death of a flashlight, but the Phoenix Arises

Flashlight Modding and DIY Parts
1

Copper is a state of mind, Laughing out loud . I guess I have a Copper Attitude right now. This build is going to test my patience, as I have not a clue as to, how or if it will work out. I usually have it already planned out, but I just can't see the finish line here... yet.

3c1

Here's a teaser, with the major components labeled.

Copper is a state of mind, Laughing out loud . I guess I have a Copper Attitude right now. This build is going to test my patience, as I have not a clue as to, how or if it will work out. I usually have it already planned out, but I just can't see the finish line here... yet.

3c1

Here's a teaser, with the major components labeled. Good luck on figuring it out!

I will be back when I know something!Wink

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08-21-2012

So, I have decided to do this as a rechargeable light, with a charging port. It's a lot easier for me, to do it that way.

I have gotten a little (very little), done on the head and here's the photos:

h1

Judco Switch

h2

Charging port

h3

Inside view

h4

I had to use a piece of 1" pipe, inside the 1" coupling, to make a tight ring for the P-60 drop in.

h5

I will have to do some fine tuning to get the reflector in, but it will be tight.

Next up is making the copper heat sink, to hold the pill and touch the sides of the head.

Does anyone have a 28mm glass lens?? Anyone? I need one, or I have to make a plastic one again. 28mm, 27mm, or 26.5mm would work

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Did some soldering and working on the wires today. Not much time, gotta go.

aq

bq

The replacement light build is now showing in post #42-43.

BLF menber Sardion Master passed away on 8/18/12. More info in this thread.
2

Reserved

3

I’ll give it a try, you are making a 3 x AA flashlight with one cell in each of the 3 tubes, the rest is to hold the dropin in place.

4

^Beat me to it!

5

3AA - yes.
Coupling holds the drop in, but the cap has to be the tail cover and what are the magnets for? Magnets don’t stick to copper.

6

its a magnetic switch :wink:

7

Ok, I see no switch, no lense, no inch tubing so the coupling and end cap is throwing me, also the brass part of the pill just looks like an end cap, but its part of a kit…… Can’t wait to see the reveal :bigsmile:

8

Is it going to be a “mule”?

9

No more soldering, everything else will be press fit and held together by magnets? :D

10

I'm gonna go with a magnetic switch as I don't see any switch parts there.

11

Well, I haven’t figured out the switch yet, that’s why it’s not in the photo. The big problem is the fact that the three tubes soldered together present an issue, as they are not one round, but more like a three leaf clover, so the end cap cannot fit over and be twist locked into place very easily. I am thinking that if I can embed a magnet in the end, between the three tubes and embed one in the end cap, it will become a magnetic fit tail cap, just slip it on and it stays on. I don’t really think that will work, so the other option is to use a small screw with a knob head, for easy turning, on the end cap and a nut in between the tubes. Most likely that will be the end result, after messing with the magnets.

I will probably put the switch in the head (coupling) somewhere, as a side switch. Just not sure yet.

12

Interesting, couldn't you get a second end cap and chop of the end part so it just is a tube that fits over them and then it would be round. And another thing I was wondering is a half inch is equal to 12.7 mm so I don't think a AA would fit inside.

13

You could try getting 3 end caps and grinding the sides to the right angles. Then solder them together so they’ll fit nicely on the 3 tubes. Leave a rectangular hole or something in the end tube. In the tube area, you could have a flat key. To secure the tailcap, you place the tailcap in so the key fits through the hole. Then you twist the key so it locks the tailcap in place.

14

I have no idea where this is going… its really interesting though!!

Good luck OL!!

Just a little tip… I have used JB weld metal stick for all kinds of metal repairs. Its like play dough you can hand form and use to fasten metals. It makes a good hole / gap filler between metal surfaces thats easy to grind, shape and paint.

15

Interesting as always. Can't wait to see the finished O-L mod.

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count me in! lol

17

Maybe it's a copper mini reverse version of the tk45 with 1 xml on the other end.

18

This is thin wall copper pipe. The ID is 14.34mm. An eneloop slides in with no drag.

19

Yes, I tried that a few months ago, when I first gave up on this 3AA idea. I found that the solder just wasn’t strong enough in the long run and fit was a big bear to do. I mean a big bruin, grizzly, wrestling bear. LOL.

I like the key idea.

20

:party: :wink: