I love AA flashlights, but most of all I love to have something to do. Modding lights is something to pass the time. I only use hand tools, no drill presses, no lathes or any other large shop tools. It takes time to hand fit stuff, but that's what I have plenty of- (time to burn).
Most 3AA lights are 3 single cells inline (like the Mag-Lite 3AA), which makes the light long & skinny. I like 'em fat (flashlights I mean)
. 3 cells side by side making short a "1D cell Mag-Lite" sized barrel... But there's not many out there that can be had. I like the looks of the SA-305, so I decided to mod one with an XM-L T6 emitter. 
I thought I would start a thread and show the build as it develops. Of course since the DX stuff "just shipped", I'm looking at a good 14 days till it gets here, but I'm starting the thread anyhow, to build up a little suspense...
I ordered an SA-305 from DX and along with it I ordered an aluminum MOP reflector and a glass lens. Now the reflector and lens will NOT fit as drop ins, so I will have to MOD either the light itself or the parts to fit.
I also ordered an 8X7135 driver, extra AMC7135 chips and a T6 emitter from Illumination Supply(IS). I have to thank them, as the items shipped Priority and they were packaged well beyond what I expected. (Small flat rate box with plenty of bubble wrap!). Hats off to Illumination Supply!
Here is a photo of what came:
The Driver is a NANJG 105C and I plan to remove the diode for surge protection/reverse flow and piggyback 1 more AMC7135 to up the amperage to 3100mah (roughly). I may not even use the driver, but that will be decided when I test the emitter direct on 3AA NiMHs.
The main reason for me doing this build is to fill up the empty hours with something that lets me use my hands to complete. I will be doing mods here that no one in their right mind would do, but it's all just for fun and for the learning experience, for me. Things such as modding the stock battery holder contacts to all copper (including making copper springs), making a heat sink out of copper water pipe fittings and replacing the tail cap spring with a handmade copper one will all be shown here.
When I am done with the build, I will list all the components I used and where I got them, as well as the other supplies like copper, thermal compounds, tools, etc.
This thread may get long and it will be done in stages, so I will reserve the next few posts for the build.
temps below freezing for the next few days. (So the weather people say)
. If that happens, I probably will not finish the build till it warms up. Garages in TX aren't insulated!
again. Oh man, I was hoping I wouldn't have to do this!
