Does it make sense to DIY pot a flashlight driver? If so, with what?
some members use some kind of rubberized paint to go over connection points like the solder joints, etc.
the general concensus here is to not pot, because many actual potting techniques are **semi permanent. Are you planning on extreme use where the electrical components might fail before the body, switch, seals, or lens?
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Just as a general longevity support - just like lubricating the gaskets - no plans for mods, the idea is to take care of the light. But maybe potting is not the right step in this direction?
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depends…newer, and possibly better emitters/components might come out that you want to stick in an older form factor, like Novatacs…the potting could be a nightmare lol. I’ve found that soldering flux seems to eat away at the Novatac potting when heated to soldering temps, and turns it into an almost oily dark brown substance, but dry heating turns it into crust crispy burnt bits.. It’s SUPER messy, but perhaps a ph-neutral rubber/silicone or even thermally conductive claylike gunk as alternatives might work.
Unless you’re trying to build something Malkoff-esque, then some basic circuit would be much easier to maintain than complex drivers and components. Have you seen Frazlabs? I’m infatuated with the simple mechanical design, where the only real electrical components are the battery and the LED, and maybe the variable resistance QTC.
**edit add:
If absolutely necessary, you could probably embed high value resistors into silicone or some insulative material to replace the brass piston slugs/QTC, and run it at a set regulated current for days.
In my experience, the electronic parts on a computer board are not mounted so loose they will detach themselves form the board. With one exemption: the inductor coil. Most items are soldered on both ends. Or on all ends 
But with budged boards it is just a roll of wire (with maybe a ferrous core) that hangs loosely above the board. The two thin wires that conduct the current snap easily because the coil itself is seldom fixated to - or supported by - the board.
You might try to apply some kind of rubber glue to dampen the movements a bit.
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Since i’m modding a lot of Zebralights, i am using this product:
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But say water ingress: would potting save the day?
It’s not that theoretical: I lost a laptop to a monsoon a few months ago.
Any pics of it cured after applying?
possibly for a flashlight. There was an older Elzetta Malkoff video where the flashlight with a potted m60 was dismantled underwater, then reassembled while still underwater and worked. I don’t remember if it was distilled or tap.
So, the short answer is maybe, if you can protect all the other components as well. An intrinsically safe flashlight is probably your best bet for a potting project, as they are generally spark resistant and" heavily" sealed.
thanks for the removable conformal coating potting compound info.. I found their USA website (parent company is in Italy).. they have several products, here are a couple of them:
magic rubber, thermal rated to 200C, looks like what Zebralight uses.
techno-gelgum, less expensive, also rated to 200C
afaik these conformal coatings are two part polymers that cure into a removable elastic silicone like consistency
not the same as non removable hard potting that malkoff uses. (one of the roles of hard potting is to conceal proprietary components)
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Regarding Malkoff it looks like liquid electrical tape i often use while repairing car and motorcycle wiring.
Once cured it’s tough as hell and can’t be easily scratched.
And that thing can also be used as potting material
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almost like a thermal epoxy?
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But then the potting compound should not be electrically conductive, obviously, but my naive thinking was that it may be better if it’s not too much of a thermal insulator either.
Is there a good value of thermal conductivity (if revealed at all) that one should aim for?
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That magicrubber i use is a thermal conductor while being an electrical isolator, so yeah, use it whenever you can
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Not sure it is the best thermal epoxy but it could be
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