Mag 1D Size and 4aa - shortening

Flashlight Modding and DIY Parts
1

I’ve been working slowly on a mag and was gonna go with 3aa nimh but now reconsidering to 4aa nimh.

I want to cut it down and put the stepped type of joint the old lumens does with the human lathe method. I do have access to a lathe here at work though. Just wondering if I bore it out will it make this joint too thin ?

My plan is to mount an xm-l to a copper heat sink I made and drive that with an east-092 driver fed from 4aa nimh.

I’m still using the stock reflector and lens for now.

Thanks

2

Yes, if you bore it, it does make the joint thin. What you have to do, is to keep the joint towards the outer part of the body. Remove a lot of material from the inside of one piece, so there's only about .050" wall left at the outside, then only remove that .050" off the outside of the other piece, to slip it in. That keeps the joint towards the outside, so when the inside is bored, it doesn't get paper thin on the inside of the joint.

Boring needs to be about 1.375" ID, if you are using eneloops.