Remember that Magcharger Mod? Now it will be a chance for someone to get a Magcharger, LOL.

Flashlight Modding and DIY Parts
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I decided to just give up on incans, since they are really all washed up. I can change that Magcharger into an led light and it will be brighter than even the hot rod bulb.

ew1

So...... get rid of the bulbs and replace them with this,ew2

Cree® XLamp® XM-L EasyWhite™ LEDs 4000K U4 XMLEZW-00-0000-0B00U440H

DC Forward Current (6 V) 2000mA

Forward Voltage (@ 700 mA, 85 °C, 6 V) 5.7V to 7.0V

Why?

It will work with the voltage of the stock NiMH pack

It's not super expensive

Mouser has one in stock

One of the CNQG aluminum reflectors fits right in the head, with the stock thick glass lens

I can parallel a couple 7135 drivers, to get some regulated current No I can't. That won't work, so it's either a 6V driver (which I don't have, or Direct Drive. Well, I have to think on that one, or ask someone who is smart.

I can stipple an aluminum reflector, if needed, to get rid of the dark spot in the center, due to the four dies.

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luminous flux @ 2000ma - 225% of std. 340ma, or 765 lumens?, so what will it be at 2800ma?

The LED is on the way. In the meantime I will be gutting the Magcharger once again.

Photos later, as I mod the head and upper body/switch.

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Added 11-30-12

It has been onehelluvaweek! I have not done much and haven't even thought about flashlights, but tonight I did manage to get a little done.

I decided that with the age and condition of this light, that I might as well start from the ground up, so I stripped the ano. I imagine there's not many polished Magchargers out there, but there will be one soon.

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I'm still working on polishing, but the ano is all cleaned off now.

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For the heat sink, I decided to make a copper star and TexasLumens was kind enough to send me a copper star from one of his builds. It was a solid star and I used files to cut it down, so I would have a center high spot for the XM-L center pad to sit on. I will solder the led directly to the star and the wires will be soldered to the led as well. This will hopefully give me some good heat transfer.

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The star is held on by two 3mm screws to the aluminum heat sink.

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The heat sink fits right into the upper body section of the Magcharger. This upper section is very thick, so all of it together makes one massive heat sink.

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I am using one of the CNQG aluminum reflectors and I had to use a copper wrap to make it a tight fit.

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I actually got the thing lined up fairly well. You can see the center rail of the copper star lined across the led hole in the reflector.

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I cut the post off the stock switch housing and I have soldered the leads to the housing and switch. Basically, I am just waiting on the led to arrive from Mouser.

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Oooo, this will be interesting, thanks for posting. 8)

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Old Lumens and the Mag rides again……gotta love it. :slight_smile:

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Updated

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You never sleep, huh?

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He must cat nap 24/7

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Ive gotta ask. How did you hold the star while you filed the sides of it? I honestly don't know how you do that. Is the raised section 1.6mm (1/16'') wide and a little less in height?

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Bah...sleep is entirely overrated... Tongue Out

Looking great, Justin! A co-worker recently gave me his old magcharger...it's been sitting in my drawer at work waiting for some love. I really like the polished look so far...you're giving me ideas!

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What is battery life going to be like when this thing is complete?

I’m very interested!

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What’s the price of the led?

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I held the star with my vise (leather lined jaws) and filed one side at a time. I didn’t measure, I just started filing and then did the fine filing after it was roughed out. I went deep enough to give room for the 22ga wires on the underside.

It all went to hell though, as I will post in the thread.

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It was $7 plus USPS first class shipping.

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This light has been one of those builds one would rather forget. It has been that way from day one. I have now finally solved the problem. I give up!

I put the led to the copper star, resulting in damaging two of the four dies, due to heat. Of course, the other two fried when I turned on the power. I knew they would, I just wanted to finish it off.

Nothing has worked with this mod and it's because I wanted to get fancy instead of sticking to the basics. A regular star would have worked fine, but I had to make a custom one. Same with the mod to the Phillips bulb, just couldn't leave well enough alone. I am my own worst enemy.

I want to throw the whole thing in the pond. I even walked out there with it and imagines throwing it in the pond and hearing the splash! What a wonderful fulfilling sound!

But... I couldn't do that. I have probably a hundred bucks in this thing and it's "so close". I just don't want to touch it, see it, smell it, hear it or know it's here any more. So, I am going to offer it to anyone, for the price of shipping. I will give it away, for shipping costs to the new owner. Someone who wants to mod a Magcharger can get one ready to go, except for a led and driver. That's got to be a deal for someone here. I will do it as a giveaway, so that it is random.

That's all folks, I will post the thread for it later.

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Bugger, bugger, bugger, splash and bugger again. I'm going to turn the computer of in sympathy and go and draw my next light.

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I’ll take it

Edit: got ahead of myself haha… Saw give it away at cost of shipping and got excited… Maybe I’ll finally win something

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Jumping the gun there my friend. Dont worry I almost did this as well. Got to beat out Scaru lol

He will be posting a thread for it at some random time.
So if you really want it you might wanna make a couple of pots of coffee.

This mad scientist never sleeps

lol
Fixed it on ur own as i typed lol

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Yeah I know, seen how quick these go. But honestly, I don’t got the money to buy one of his beauties… Thought I hit the lotto for a min lol…

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For a driver, I’ve used the KD super output P7 driver though it works best with 6 nimhs (8.4V max)or 2 liions. 6V is a bit of a tweener to work with. Really sorry to hear about the problems.

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For a driver, I’ve used the KD super output P7 driver though it works best with 6 nimhs (8.4V max)or 2 liions. 6V is a bit of a tweener to work with. Really sorry to hear about the problems.

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This driver Garrybunk located at fast tech might be just the ticket for an easy mod for all those 6V halogen (Niterider, Vistalite, et al) bike lights or Mag Charger lights out there.