Custom P60 14500 XP-G2.. Night shots added. Temporarily XM-L with Old-lumens reflector.

Flashlight Modding and DIY Parts
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I'll let the pictures do most of the talking on this one. I wanted something different for a left over P60 reflector . This has a XP-G2 LED and a KD 7135 6 V2 driver.

All the machined parts.

Along with the other parts.

The Tailcap was intentionally built oversize as it looked better than the smaller tailcap. It measures 25mm Od and 24mm long. The drive screws do there job tailstanding and to stop it rolling. I had better luck with the knurling this time.

Insert pill and reflector here.

The lens retainer with coated 28x2mm lens.

Tailstanding is not a problem.

To give you an idea how big it is, left 18650 and right aw 14500.

Left L2M in short form for a 16340 battery and right is an Ultrafire 504B.

The left and middle lights are 14500 and the right light is an 18500.

The build has not turned out as planned. The XP-G2 I put in this light and the reflector did not cooperate as planned. I knocked to chips of the driver to lower current output to 2.2 amps on hi and the led went into melt down turning a very bright white where medium was a very nice tint in 3B. The reflector was for an XM-L and before I put the notch in the opening for the reflector I scratched the reflector surface slightly trying to get it out on initial fitment. This showed up badly in the beam and the reflector did not match the XP-G led either. I have another reflector on order to suit the XP-G so this will have to wait. The flashlight on the left above kindly donated its pill,driver and LED to run in this light for a short time. To fix the reflector scratch the reflector was given the Old-Lumens fix and sputtered with hair spray. This fixed the scratch and gives a very broad spread of light. Tonight I got a couple of beam shots. To give this light some real competition I pulled out the HD-2010. To say the least I was not surprised at the results.

Mouse out is the P60 14500 and mouse over the HD-2010. It sure gives it a run for its money.Laughing Distance to the bush at the end of the driveway is about 65 meters.

On the left is the HD-2010 and right is the P60 14500. There is no hotspot at all with the sputtered lens.

Thanks for looking.

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Very impressive machining skills you have there.

I'm impressed, to say the least.

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Wow! You are literally turning them out at high speed. And they look good too :-)

Looks like an awesome little light cannon. How do you like the XPG-2 in it? And how does it handle the heat on high I wonder ?

Good job I'd say. Good indeed!

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Nice work.

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Thanks Chicago X.

Ledsmoke. I don't think I will have a problem with heat as it will only be driven at 2.2 amps if I'm lucky. My bad luck continues with soldering as the light has 3 modes as expected but they are all very dull. I will have to do a bit of problem solving tomorrow. If it gets to hot on high there's always medium. (Smiley inserted here. Can you see it. Nothing works correctly on IE10).

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I've been sitting here awhile swapping caps wondering why I liked the bigger switch cap on the P60 and all of a sudden it hit me.

It looks like a scope. (To me it does anyway).

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At last, a p60 light I like…… :bigsmile:

Seriously though, I really love the line of lights you’ve premiered recently dnf, their all awesome. Hell, if you were selling these it’d convince me to buy some 14500 cells just so I could own them. Thanks for sharing. I do particularly like your tailcaps and I agree, the form is very scope esq. 8)

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Night shots added to the opening post.

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Ha! Thats exactly what I thought when I saw it first time around. It just needs 2 turrets then its a scopelight!

It still looks very very nice though. I'd love to have me one of those for sure.

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What an amazing light! Well machined and gorgeous. Job well done! 8)

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Very nice light. The beamshots of this light and the hd2010 seem to complement each other, the two together would prove an ideal car-light .

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That light has a very unique look. Nicely done! Excellent scratch build.

The build has not turned out as planned, LOL. I think that to myself, about mine, just about every time I do one...

Do you think you will ever take a shot a anodizing? I'm waiting for someone here to do that. There's a ton of different colors out there. I bet you could do some crazy stuff with that!

Thanks for putting up this build thread on BLF.

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Thanks JohnnyMac.

djozz. I had not even thought of that, car headlights. It was done tongue in cheek . I'm easily amused and need a bit of a chuckle right now.

Old-Lumens. Thanks also. I've been playing around this morning and have now taken three chips of the driver giving it an output of 1.9 amps on Lithium Ion and 1.6 on a lifepo4 battery. Put an extra long 18mm diameter reflector along with the XP-G2 into the far left silver torch above in the first post. The tint is now ok on hi and looks pretty good in the daytime here. I may have to take some more pictures tonight if its not raining.

About the anodizing. I reckon that I would need a good tutor and instructional videos to help me with that. I have someone in mind but don't know if they would be willing. Smiley wink here. (Smileys don't work in IE10)

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Naw, all you need is a kit.Wink

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Thanks. I have now spent $1100.00 on an anodising kit. (NOT). Looks like a nice kit but way out of my price range. I have Googled previously and not found anything that was really cheap. I thought oven cleaner may do something but the caustic soda must have been taken out. As a kid I remember cleaning a carby in caustic soda used to clean the milk lines and needless to say it turned it into a black mess. I could get my daughter to paint them with nail polish. She did a good job on this one I did think. (The nails that is). Dont I just have the daintiest hands. (Swapped to Firefox. Smileys work here).

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Just catching up on old posts after the holidays and I run across this... Darn nice build! That is one nice looking little "P60"....(and very nice knurling too Smile )

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I hope you had a terrific holiday Match. Thanks for the compliment. Its still a work in progress. The XP-G2 led used will not take current like previous ones I have used and its the last one I had. Its now running in the dodgy knurling flashlight (the knurling on that is now fixed as well after making a mandrel up to take the load) at 1.8 amps and still turns from a nice warm tint on medium to a bright white light on high. A reflector and LED's are on order.

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beautiful looking light there MRsDNF, I wish I had those skills (and thread cutting abilities!). This is a great read on anodising small batches and it doesn’t look like you have to spend a lot of money to do good work. I’ll probably just put my next piece out on a beer’n’chocolate tender as I don’t make enough to make it worthwhile to do it myself, but it looks like you’re busy enough to justify the $100 or so needed to get started.

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Thanks matthemuppet. I have just spent an hour reading this again and its very interesting. I may have to wait until I retire (which wont be any time soon as the Mrs does not want to get a fourth job, why I don't know) and create another hobby. Cheers.

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I can see that. For me, it’s the worry that I’ll blow myself up or melt off a leg or something as I’m a bit on the accident prone side. Still, there are several very friendly peeps on that forum dahn unda that I’m sure would be happy to throw an extra piece or two into the etch bath :slight_smile: