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So I had read about the XP-G3 horrors before I purchased this light but I must’ve forgot. I was genuinely surprised how bad it was which prompted me to do the pictures…
I pondered and wondered on what I should do. Don’t know if my sister would notice it but if she would then I don’t think she would be able to unsee it.
So let’s go for a emitter swap then. Let’s open it up first…
And we’re in like sin.

How: A cutter and some patience. I didn’t need heat. Don’t go too deep with the cutter. Start on the flat side seams, gently at first until you make a groove for the blade to ride in and go around until you can feel your cutter going through the plastic. Then go for the corners. I took my time doing this, maybe 15-20 minutes and left barely any marks on the plastic. It’s tight but you can get it open without marring anything. I did marr the plastic on couple of spots because the cutter went off in wrong direction. I’ll have to smooth them out afterwards…
Nitecore is using the battery as a heatsink. 40x25mm and 2.5-3.0mm thick thermal pad which was glued to the PCB from one spot, see the red residue and thermal pad material left on top the component on the PCB.

Yup, an 1800mAh battery. 103650 size, not sure if it has built-in protection.

Grainy close up of the PCB

Brains of the operation

Da front

Separate MCPCB, 1mm aluminium

No thermal paste… A dab would do, like, you know, air is bad at like 0.02W/mk. Even toothpaste is better. Or mustard. Or ketchup. Or anything but air.

I don’t really have a lot of options for the emitter swap. Obviously I could order something but it’s already 27th so I don’t think it would arrive in time for christmas.
What I do have is that shitty AA led+cob flashlight into which I stuffed an Nichia 219BT-V1 5700K 90CRI from Kaidomain on a 16mm MCPCB. I could reflow it off of that onto this… Especially considering I broke it’s switch early this year so it’s just sitting there collecting dust.
I’ll have to think for a bit. I’ll probably go for the 5700K 219B option. It’s the fastest solution and best option I have right now. Funny thing is, I’ve been meaning to order solder and flux for a long time since I’ve kind of run out… I do have some stuff but not sure it’s appropriate for this kind of thing. What could possibly go wrong… At least the LED is on a separate MCPCB so I can’t really fuck up the PCB of the light itself.
P.S. Didn’t take a picture of the optics side of things but the reflector is 16.7mm wide and 6.7mm deep, o-ring is 1mm thick and as wide as the reflector while the lens is 1.1mm thick.