Very cool design idea to use copper wire to create a flashlight body!
Hopefully you can figure out a way to make it work. Maybe try Kapton tape?
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What about baking paper wrapped around like a kebab lol?
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Or maybe some silicon spray on the bolt. There are some that leave s sort of dry silicon lube when the carrier evaporates.
Just something to keep the glue from adhering well to the bolt?
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So I combined about all your ideas:
I did bolt “Maki” - I have wrapped the screw with plastic wrap then add some grease, wrapped some more and created some layers of plastic and grease.
After everything was covered I wrapped it with the copper wire. It pushed all the grease toward the end of the screw.
Then, I have covered everting with a thin layer of clear Epoxy glue.
Now I have to wait for it to cure and check if I am able to take out the screw.
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I forgot to update that the grease made it much easyer and I was able to unscrew it from the bolt
I have also made the “Pill”.
Using a hand saw I cut a short section of the screw
I have used the nut to keep it stright.
And drilled 2 holes for the wires
Had to sand it a bit to remove sharp edges
I continue working fast since only 2 days left.
Drilled a coin to close the bottom end and hold the switch and boot.
And also solderd a spring fo the switch
Then soldered the switch in place
And close the bottom part by soldwring the coin to the body
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Oh my gosh this is great! What a fantastic idea for a truly scratch built light just using what you got. Reminds me of my early days in this hobby. I might revisit that and make a light like you are out of aluminum and copper wire. Will be following it and looking forward to the end product.
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Thanks. Be prepared for a lot of frustration
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After the switch I worked on th pill.
Solderd some piece of cupper to the driver in ordet to have place between the board and the pill for the components
Then I solderd the dtiver to the pill and glued the MPCB to the other side. And soldered the LED
And finally I have tested it
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Less then 7h left for the deadline.
I have to cut the body to 2 parts to enable replacing the battary without taking the evrything apart.
Unfotunately, it broke the glue and trying to screw the pill just made things worse
In the time left I will glue it a gain and add the optics.
If I have enough time I have an idea how to make it stronger and nicer
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For the optics I wanted to use spot lens but the only tight lense I have is 21 mm and did not fit so I had to take it out of the holder
I also had to cut the wire tube in order to make it fit in length. This time I screw the bolt into the wire in order to make it stronger so it will not break the epoxy
And placs the lense inside
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Nice work there! the lens looks good. does the light function yet?
Now I have to re-wrap the edges re-glue them.
Since it is short sections I belive It will not be a problem to unscrew the bolt.
And now waiting for it to cure…
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Same
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Everythig is now dry and ready for assembly.
I have to admit it is not at all looks as I imagine it but it is nice add to my lights collection.
I like the idae that this is a functioning 1000 lm thrower made entierly frome acratch from nothing more than a copper wire, Epoxy and a screw.
If i had more time I would have add another wrap of wire to make it shiny
Hope to make a better looking light next year.
As always thanks a lot for the orginizers and lets remember Old Lumen
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Congrats on getting a working light from your concept. Much better than what I did…which was nothing.
But darn it is not pretty… 
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Wow, you did it YuvalS! Good job finishing the build.
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