11-6-09 UPDATE:
I completely disassembled the light and used the acid wash that Sarge suggested to neutralize the etching due to the battery leakage. I then used stiff nylon bristle brushes to scrub out the excess crud, followed by a thorough wash with hot, soapy water. Althought the inside of the barrel looks pretty rough in a couple large areas near the tailcap end, the switch assembly is untouched and the tailcap is in better condition than I thought--the threads are completely intact, and the only corrosion on the cap is a small area where the battery spring seats. The O-ring seat on both the tailcap and barrel are fine, and the tailcap threads on the barrel are in good enough shape that thread engagement isn't an issue. She should have a few good years left in her.
One thing I did note when I had it apart was that the tube size is quite different from a newer model 2D we have (the newer model as the "D" prefix on the serial number). The heads nor tailcaps are interchangeable. I measured both lights with a caliper and got these numbers:
Old model: barrel OD 1.640", wall thickness .134", head ID 1.645"
New model: barrel OD 1.550", wall thickness .105", head ID 1.555"
Holding the two lights side-by-side you can easily see the tenth of an inch difference in diameter. Interestingly, the outside dimensions of the heads, both diameter and length, are the same.
Original post:
I have a 4D Maglite that I've owned for more than 25 years now (got it for my 16th bday). My dad purchased it from Wald's Police Supply in Dallas, and it bears the Wald's stamp in the barrel. That light accompanied me on many a campout and road in every car I've owned through the years. Needless to say, it has sentimental value.
These days I get much more use from LED lights, but the trusty Mag still rides in the car. Pulled her out the other day for some reason and got no joy when I clicked the switch. Thought the bulb might be shot, so I pulled the tailcap to replace the bulb. That's when I discovered that two of the batteries leaked and etched the inside of the barrel. Unfortunately, the leakage got into the threaded area at the tail and ate some of the threads on the tailcap. Thankfully, the etching didn't make it to the O-ring seat, so it still maintains its water resistance.
I can still screw the tailcap into place, but it's a gritty travel. So, my question is do I have any recourse to address the damage done by the battery leakage? Is the answer to live with it? Will it get any worse over time on its own? I'd like to keep the light and keep using it rather than retire it as a wall hanger, but I'm just not sure what my best course of action is. I appreciate any advice you all can give.
Regards,
Scott
I completely disassembled the light and used the acid wash that Sarge suggested to neutralize the etching due to the battery leakage. I then used stiff nylon bristle brushes to scrub out the excess crud, followed by a thorough wash with hot, soapy water. Althought the inside of the barrel looks pretty rough in a couple large areas near the tailcap end, the switch assembly is untouched and the tailcap is in better condition than I thought--the threads are completely intact, and the only corrosion on the cap is a small area where the battery spring seats. The O-ring seat on both the tailcap and barrel are fine, and the tailcap threads on the barrel are in good enough shape that thread engagement isn't an issue. She should have a few good years left in her.
One thing I did note when I had it apart was that the tube size is quite different from a newer model 2D we have (the newer model as the "D" prefix on the serial number). The heads nor tailcaps are interchangeable. I measured both lights with a caliper and got these numbers:
Old model: barrel OD 1.640", wall thickness .134", head ID 1.645"
New model: barrel OD 1.550", wall thickness .105", head ID 1.555"
Holding the two lights side-by-side you can easily see the tenth of an inch difference in diameter. Interestingly, the outside dimensions of the heads, both diameter and length, are the same.
Original post:
I have a 4D Maglite that I've owned for more than 25 years now (got it for my 16th bday). My dad purchased it from Wald's Police Supply in Dallas, and it bears the Wald's stamp in the barrel. That light accompanied me on many a campout and road in every car I've owned through the years. Needless to say, it has sentimental value.
These days I get much more use from LED lights, but the trusty Mag still rides in the car. Pulled her out the other day for some reason and got no joy when I clicked the switch. Thought the bulb might be shot, so I pulled the tailcap to replace the bulb. That's when I discovered that two of the batteries leaked and etched the inside of the barrel. Unfortunately, the leakage got into the threaded area at the tail and ate some of the threads on the tailcap. Thankfully, the etching didn't make it to the O-ring seat, so it still maintains its water resistance.
I can still screw the tailcap into place, but it's a gritty travel. So, my question is do I have any recourse to address the damage done by the battery leakage? Is the answer to live with it? Will it get any worse over time on its own? I'd like to keep the light and keep using it rather than retire it as a wall hanger, but I'm just not sure what my best course of action is. I appreciate any advice you all can give.
Regards,
Scott
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