Maglite LED and incan mods and drop-ins, Overview

I know there has been a few "Searching for Maglite Upgrade threads" so Cydonia decided to ask me to start a thread as a quick guide/list of drop-ins and mods so everything is relatively together. (stickie?)

Feel free to post and add more info.

TigerhawkT3 said:

.....
Incan:

There are lots of good bulbs to use. Look for products from Osram, Philips, GE, Sylvania, and Welch-Allyn. These are only a few manufacturers out of many, so keep on the lookout.

Try www.bulbconnection.com. They carry lots of bulbs, and have at least some specs on most of them. They also have a great search function.
.....
Most high-powered incan mods will need an aluminum reflector (available from CPFer fivemega or www.kaidomain.com) and glass window (available from www.flashlightlens.com or www.kaidomain.com). Bulbs above 30-35W or so are likely to melt the stock plastic components.

Few bulbs have a standard PR base (the ROP bulb being an exception). The most common base for high-powered incans is a bi-pin, as seen in the stock incan Minimag. Of course, these are much more powerful, so you can't just drop them into a little plastic socket. There are two main options: get a PR>bi-pin adapter, or replace the entire bulb socket. You can get an adapter from fivemega or www.kaidomain.com. The second option, replacing the entire socket, requires more work, but is usually cheaper and more effective. The solution I use is CPFer kiu's "high-temp socket."

Ordinary alkaline batteries are pretty much out for most incan mods. The most popular solution is using NiMH AAs, either in an adapter or permanently assembled into a pack. For adapters, look for fivemega's or modamag's work. For custom-made battery packs, contact CPFer LuxLuthor or try www.cheapbatterypacks.com. The advantages of an adapter are that you can remove the cells from it and charge them individually, while a pack may be easier to handle and capable of higher current.

If you want to pack four AAs side-by-side, you'll generally need to bore out your Mag (for a greater inside diameter). Boring is also necessary for 2/3A cells (see www.cheapbatterypacks.com for more info on this size and other cells).

One bulb I'm using is the hundred-watt Osram 62138, which is used in the USL. The USL is a 2D Mag holding 11 high-current AA NiMHs, with a few thousand lumens of output. My version uses 12 weaker AA NiMHs in a 4D (with an LM317T-powered LED sticking out of the tailcap for a low mode). The 62138 is a very nice bulb, but there many others.

Remember, incan mods can pack some serious power, so please be careful.

LED:

The main issue with LED Magmods is the heat. The heat produced by an emitter (or emitters) must be moved away from it somehow, and that task is very difficult in the stock Mag bulb post. Even Mag's own MagLED has built-in thermal throttling, which decreases power as the unit heats up in order to prevent it from being damaged by the heat. For this reason, high-power LED mods generally pack a heatsink into the entire width of the Mag tube, to transfer heat from the emitter(s) to the heatsink, then to the Mag's body and into the surrounding environment.

To make your own custom mod, look for a heatsink from CPFers H22A, modamag (modamag's work is available at the Sandwich Shoppe), or others. These allow you to choose your own emitter(s) and driver(s) for a personalized touch.

One driver I've found handy for LED Magmods is the LM317T, available at RadioShack and www.kelvin.com, among other places. It allows you to power your emitter(s) with constant current, determined by a resistor or pot. Examples are the Birthday Mag (link, link) and EZ-Dim (link). This driver is cheap and easy to use, but is less efficient than many other drivers.

Another method to control the output of your LED Magmod is a simple resistor. Use a resistor calculator to determine what value(s) to use.

Minimags:

There aren't too many mods available for the Minimag. Most focus less on raw power and more on practicality. They generally have a bi-pin base (like the stock incan Minimag bulb) and an emitter, with a driver in the middle. Another old LED drop-in is the Opalec Newbeam. To my knowledge, there are no incan mods for the Minimag more powerful than the Auroralite hotwire kit.

...Yet. :devil:

Click to expand...

Solitaire:

LED:

• SmjLED drop-in
  • Improves output to around Arc AAA(CS version I think) output.
  • Improves runtime
  • Sellers: Lighthound(2% off coupon "CPF", not sold anymore)
• Tektite LT-3
  • Improves output and runtime.
  • Sellers: LED-replacement.

Other:

• Strike Anywhere mod
  • Fill the inside with strike anywhere matches instead of an AAA battery.
  • More output then stock
  • Can actually start fires
  • Provides a water resistant match tube:

LED mods:

• XP-E 10440
  • Small and bright
  • Runtime depends on battery quality and resistor
  • Aspherical version
• XP-G 10280
  • Smaller then the above mod
  • Runtime also dependent on battery and resistor
  • can be made to work with a 10440.

Minimag(2AAA):

• Terralux TLE-20
  • Decent output, good runtime, also fits the 2 AA minimag(and has the fitting reflector).
  • Might be possible to swap out the LED for something brighter.
  • Sellers: Batteryjunction(coupon code "CPF2006" for 5% off)
• The SmjLED drop-in for the Solitaire fits but you'll need to use 1 AAA battery. 2 will fry the drop-in.
• I've heard the SmJLED drop-in for the 2AA Minimag works too, but you'll need to modify the reflector. For the drop in, look at the second bullet under Minimag(2AA)

Minimag(2AA):

LED:

• Terralux TLE5EX drop-in
  • Good output but lacking a bit in heatsinking
  • Sellers: Batteryjunction(coupon code "CPF2006" for 5% off)
  • Green and Red LED(links to Batteryjunction)
• Super MJ LED drop-in
  • Decent output, heatsinking is not a problem, good runtime
  • Sellers: Lighthound(2% off coupon "CPF", not sold anymore), Sandwich Shoppe
• Terralux Ministar2 TLE-5UV, Ultraviolet drop-in for the Minimag.
  • Sellers: BatteryJunction(coupon code "CPF2006" for 5% off)
• Nite-ize 3 LED drop-in
  • Floody and similar output to the stock maglite. Good runtime. Nite-ize info.
  • Check your local stores.
• Nite-ize "1 watt" drop-in.
  • Decent output for a Luxeon I(III?). Decent runtime. Info from Nite-ize.
  • Check Target and the like.

Incan:

• Auroralite hotwire mod(review).
  • Very bright but short runtime and requires a few parts.
  • 2 14500 batteries and a charger, Kit, lamp.

Other:

• Disabling the twist on-off switch(constant on).
  • Good for the talicap switches.
  • Try a washer of the right size under the "Do Not Remove" plastic piece. The washer should prevent the reflector from pushing down on the lamp holder and turning off the light.
• Video of an Edison KLC8 LED swap/drop-in in action.
• Acrylic Ball
  • Increase throw when the source is at the right focal point.
  • If not at the right focal point, it creates a nice round beam(presuming just the source and no reflector).
  • Here's the link to half of an acrylic ball.

MagDs and MagCs

LED(Not all, just some of the more recommended ones):

• TerraLux TLE-6K2, 4-6 Cell Maglite.
  • I've heard of may different opinions, some say dim, some say bright, but my guess is that overall you shouldn't be too disappointed by the drop-in. Heatsinking is also lacking.
  • Sellers: Batteryjunction(coupon code "CPF2006" for 5% off)
• TerraLux TLE-6EXB, 2-3 Cell Maglite.
  • I've heard of may different opinions with this one too, some say dim, some say bright, but my guess is that overall you shouldn't be too disappointed by the drop-in. Heatsinking is also lacking
  • Sellers: Batteryjunction(coupon code "CPF2006" for 5% off)
• Terralux TLE-6 Red or Green
  • Red or Green LED drop-in for the Maglite. I haven't seen beamshots but performance should be at least decent
  • Sellers: Batteryjunction Red, Green (coupon code "CPF2006" for 5% off.
• Terralux TLE-300M, 4-6 Cells
  • Bright but there have been one or two reports of loose optics. The beamshots also show a weird beam pattern.
  • Sellers: Batteryjunction(coupon code "CPF2006" for 5% off)
• Maglite's own drop-ins, separate 2, 3, and 4 cell versions.
  • Good for something that you can buy at a store, but there are brighter options out there. Output drops once the module heats up to prevent overheating.
  • There might be newer Rebel versions of the drop-in. Should be brighter then the Luxeon III versions. Some of the MagLEDs with the drop-ins installed have them.
  • Look in some local stores, they should have some
  • Seoul Mod.
  • Hurricane mod, coupled with the Seoul mod should give a decent output long running light.
  • Newbie's MagLED review, lots of info.
• Malkoff devices 2-3D drop-in.
  • Regarded by most as one of the best maglite drop-ins available. Good heatsinking but expensive and hard to get.
  • Great throw.
  • Good runtime.
  • *Maglite must have a "D" infront of serial number.
  • Coupon is "CPF"
• Malkoffdevices 4-6D drop-in.
  • Regarded by most as one of the best maglite drop-ins available. Good heatsinking but expensive and hard to get.
  • Great throw.
  • Good runtime.
  • *Maglite must have a "D" infront of serial number.
  • Coupon is "CPF"
• Malkoffdevices 4-6D Quad LED drop-in.
  • Great output and should have great durability. There are four drivers in there so even if you somehow manage to break three of them, you would still be able to finish what you need to do. It's expensive though.
  • Not made anymore.
• Malkoffdevices 2-4 D or C Tri LED drop-in.
  • Great output and should have great durability.
  • Good runtime.
  • Good throw.
  • *Maglite must have a "D" infront of serial number.
  • Coupon is "CPF"
  • Not made anymore.
• Malkoffdevices 2-3C drop-in.
  • Regarded by most as one of the best and brightest single LED maglite drop-ins available.
  • Good heatsinking, improtant for LED life.
  • Great throw.
  • Good runtime.
  • *Maglite must have a "C" infront of serial number.
  • Coupon is "CPF"
• Malkoffdevices 4-6C drop-in.
  • Regarded by most as one of the best and brightest single LED maglite drop-ins available.
  • Good heatsinking, improtant for LED life.
  • Great throw.
  • Good runtime.
  • *Maglite must have a "C" infront of serial number.
  • Coupon is "CPF"
• Malkoffdevices universal drop-in.
  • Fits C and D cell lights.
  • Uses the same optics as his M60 drop-ins.
  • 2 Cree Q5s, good output and the optics provide a good beam. Sign up for his newsletters to have a higher chance of getting one.
  • Good heatsinking, important for life of LED.
  • Not made anymore.
• Malkoff C size Seoul P7 drop-in, 4-6 cells, 5-13v
  • Bright because of multidie Seoul P7(imagine 4 Seoul P4s in one package). The LED is driven at 1.8 amp.
  • Good throw with a medium sized hotspot.
  • Good amount of spill.
  • Good heatsinking, important for life of LED.
  • *Maglite must have a "C" infront of serial number.
  • Coupon is "CPF"
• Malkoff D size Seoul P7 drop-in, 4-6 cells, 5-13v
  • Bright because of multidie Seoul P7(imagine 4 Seoul P4s in one package). The LED is driven at 1.8 amp.
  • Good throw with a medium sized hotspot.
  • Good amount of spill.
  • Good heatsinking, important for life of LED.
  • *Maglite must have a "D" infront of serial number.
  • Coupon is "CPF"
• Elektrolumens "Monsterthrow" 3D cell drop-ins (Scroll down a bit and click "Monsterthrow")
  • IMO more floody then throwy. Good output but not regulated. Different amounts or LED for different runtime and output. More LEDs = more output and less runtime and vice versa.
  • No more being made from what I see. Seems to be replaced by the P7 mods.
• KD's Cree drop-in.
  • Decent output but a Cree doesn't work that well with reflectors.
  • Rings in the beam
  • Drop-in + MOP reflector and multilayer coated window.
  • Drop-in + Aspherical lens kit.
    • Good amount of throw.
    • Good flood focus, actual smooth beam without rings or holes.Essentially no spill
• Elektrolumens 3D Seoul P7 drop-in.
  • Quite a bit of output, runtime will be shorter then the other drop-ins.
  • At full focus it might have a donut type beam.
• Elektrolumens Wall of Fire drop-in
  • Lots of output. 4 Seoul P7s, equals to 16 Seoul P4s.
  • Pureflood beam, good throw for such a beam due to the amount of output.
  • He added reflectors and a larger head so this isn't a drop-in anymore.
• Elektrolumens 3D 2 Cree MC-E drop-in
  • Lots of output.
  • Floody beam.
  • Great heatsink.
  • Should have good throw for the beam pattern due to the amount of output.
  • Runtime is probably short unless good rechargeable batteries are used.

LED Mods:

• Minimag MC-E
  • Bright, small, short runtime.
  • Probably more of a "wow" light
• 2 cell Seoul Micropuck.
  • Good output, good runtime and good regulation.
  • There are different powers of micropucks so you can have the output you need. Other drivers would also work for higher power, different voltage ranges. Their connections would be slightly different though.
• Seoul mod, 3D.
  • Good output, might draw a but much for alkaline batteries (around 1 amp draw from the batteries). Should be similar to the Malkoffdevices drop-in if done properly.
  • Different drivers can be used to suit your needs and battery inputs. 2D, 3C, 6 AA cells, multimode(high, low, strobe etc.)
• Cree mod, 3D
  • Good output, simple(no driver), direct driver(dims as the batteries die).
  • Direct drive can be used for more output, ensure good thermal path.
  • Like the above mod, except with a resistor. Different resistors can be used for different runtime and output. A Seoul can be used.
• Seoul P7 Mod. Another one
  • Can be pretty bright.
  • Can do without the driver if you have the right voltage or resistor.
  • Even direct driven works.
• Seoul P7 Mod under $30 for Maglite 2C
  • Good price and the module comes with most of what is needed.
  • Bright
  • Can be adapted for other C sized Maglites.
• Seoul P7 mod for 2D maglite
• Another Seoul P7 Maglite mod
• Multimode Seoul P7 mod
  • Multimode to improve runtime if needed and for lower output
• Cree MC-E Mod.
  • Can be really bright.
  • Can be without a driver presuming the right battery voltage and/or resistor. Direct drive can work
  • Can be wired in parallel, series, or 2s2p
  • Smooth reflector can produce a doughnut shaped hotspot though.
• SST-90 3D build
  • Brighter then most of the other LED mods and drop-ins
  • No driver necessary
  • Works with a smooth reflector
  • Similar mod with Optic and Lens beamshots.
• Custom 1xD P7 with D2Flex
  • More complex then others.
  • Bright and relatively small.
• Drop-in mod.
  • I don't know how this works but some grinding and fitting should make this drop-in fit right into the Maglite.
  • Good output.
• Mag 1D SST-90 build Here's another
  • Smaller then a full sized Mag and still bright
  • Direct drive
  • Can be very bright
  • Doesn't need OP reflector for smooth beam
• Ostar Aspherical Mod
  

Incan mods(Easier ones):

• Magite's own Xenon bulbs.
  • More and white output.

• Using a 3 Cell bulb in a 4 Cell, 4 Cell in a 5 Cell, 5 Cell in a 6 Cell, no xenons. (Works with rechargeables too)
  • Higher output, whiter beam, and not too expensive. Overdrives the bulb so expect shorter bulb life. I'm not sure if a 2 cell will take a 3 cell overdrive.
• 6D cell in a 2C. 3 CR123 batteries with a adapter and a 6 cell bulb.
  • 6D output in a 2 C. You can also use 2 Li-ion batteries and a 5 cell bulb(no xenons for the Li-ion).
• 3Cs in a 2D, 4Cs in a 3D, 5 Cs in a 4D and so on.
  • Higher output and whiter beam and not too expensive. Rechargeables work too. I'm not sure if a 2 cell will take a 3 cell overdrive.
• 5 cell bulb with 2 Li-ion cells
  • Higher and whiter output without too much cost if you already have a cells.
• ROP mod.
  • Much more output but also requires a bit of work. Metal reflector and glass window needed. Batteries depends on the user and the light. High and low bulb.
  • Peilcan Big D bulb usually overdriven by a 7.2v source(6 NiMh batteries or 2 Li-ion).
• Mag85.
  • Much more output but also requires a bit of work. Metal reflector and glass window needed. A Bi-pin adapter can be used if unpotted bulbs are bought. Batteries depends on the user and the light.
  • Welch Allyn 1185 bulb usually overdriven by a 10.8v source(9 NiMh batteries or 3 Li-ion).
• Mag 5761
  • More output then a ROP. But also slightly harder, needs a bi-pin adapter. Glass window(Lens), metal reflector with a big enough opening, batteries depend.
  • 2 Li-ion battery that can handle the load or 6 good NiMh batteries.

• Threads of interest. Most powerful Maglite mods. Destructive bulb testing.

Incan Mods(more involved):

• 2D Mag 623
  • Tons of output.
  • The needed parts:
    • A Tri-bore 2D Mag Host
    • Osram 64623 (or 64633) bulbs
    • An aluminum reflector
    • A glass lens
    • A High-Temp Switch mod or switch replacement
    • A 15.6V battery pack from LuxLuthor
    • A Universal Smart Chager
    • Optional: An FM3V-2 replacement head (has alum reflector and glass lens)
    • Optional: AW's MagD Incan Driver (switch replacement)
    • Optional: A voltage meter or e-station (VERY useful-removes battery resting guesswork)
  • Thanks to 299792458m/s

Other:

• UCL window(lens).
  • Glass window(or lens if you choose to call it that). More scratch resistant then the stock plastic window and lets more light through then the stock window. Might have a visible difference depending on how scratched your stock window is.
  • Stores: Lighthound, Flashlight Lens(52 mm).
• Borafloat window(lens)
  • Glass window(or lens if you choose to call it that). More scratch resistant then the stock plastic window. More resistant to thermal shock then the UCL but lets less light through. Good when you are making a high power Incan mod for you maglite.
  • Stores: Lighthound, Flashlight Lens(52 mm).
• Metal reflectors:
  • Not much improvement in output but much more resistant to heat then the stock plastic ones(necessary for high power Incan mods). Also different amounts of texturing available.
  • Sellers/makers: Kaidomain, Fivemega.
• Maglite C tower, For C cell Maglites.
  • Won't melt like the stock plastic tower.
  • Good heat transfer, should improve heatsinking for LED drop-ins, how much I'm not sure(gaps between the heatsink and the drop-in).
  Post of some maglite C replacement parts/heatsink/better parts/attachments.
• Prefocused Mag.
  • So the bezel on tight is always at the right focus.

Magcharger:

LED:

• Terralux TLE-300MR.
  • Good output, I'm not sure about anything else. Beam shots show a weird pattern.
  • Sellers: Batteryjunction(coupon code "CPF2006" for 5% off)

Incan(simpler ones):

• Drop-in a Welch Allyn 1160.
  • Higher and whiter output. No special parts needed beside the bulb.
• Drop-in a Philips 5761.
  • Higher and whiter output. No special parts needed beside the bulb.

Here's a list of (currently available) LED PR flange bulbs started by john2551.

All should work on a Maglite C or D.

john2551 said:

I'd like to compile a list of (currently available) LED PR flange bulbs that will fit just about ANY generic flashlight. So far i have:

TerraLux: http://www.terraluxcorp.com/products/TLE1.php?PHPSESSID=229c772fc71f7f7f4e1b93fff0127f53
Dorcy: http://www.dorcy.com/products.aspx?p=411642
EverLED: http://www.flashlightreviews.com/reviews/everled.htm
PR2 WHP1: http://www.superbrightleds.com/cgi-bin/store/commerce.cgi?product=LIGHTS
SMJLED: http://www.flashlightreviews.com/reviews/smjled_bulb.htm
SMJLED2: http://theledguy.chainreactionweb.com/product_info.php?cPath=48_52_82&products_id=853
LunaLEDs: http://www.flashlightreviews.com/reviews/lunaled_2cell.htm
Tektite: http://www.flashlightreviews.com/reviews/tektite_lpr-3.htm
Tektite: http://www.tek-tite.com/src/product_info.php?id=1057
Tektite: http://www.tek-tite.com/src/product_info.php?id=1059
Nite-Ize: http://www.flashlightreviews.com/reviews/niteize_magbulb.htm
LEDtronics: http://www.flashlightreviews.com/reviews/ledtronics_prbulb.htm
TLE-20 : http://www.terraluxcorp.com/products/TLE-20page.php?PHPSESSID=4f808f65d13548315854c122c91dad71
Tektite: http://www.tek-tite.com/src/product_info.php?id=3056
Night Pearl: http://www.sinounion.com.hk/index1.htm
LEDcorp: http://www.warrencustomoutdoor.com/pl-bulbs.html
EverLED (diamond): http://www.everled.com/everled-fbr/?content=diamond (for lanterns with negative voltage)
Battery Station: http://www.batterystation.com/cpf2.htm
Nite-Ize: http://www.niteize.com/productdetail...product_id=166

MANUFACTURER / VOLTAGE RANGE / CELL # ALKALINE / CELL # NiMh / LED type
Terralux TLE-1F / 2v-9v / 2-6 / 2-7 / 1 watt Luxeon
LunaLEDs / not stated / 2 ONLY/ ---- / 1 watt CREE
Dorcy 1 watt / 1.5v-8v / 1-5 / 1-6 / 1 watt ?
EverLED / not stated / 1-6 / 1-6 / 1 watt Luxeon
SBLs PR2-WHP-1 / 2.8v-12v / 2-8 / 3-10 / 1 watt ?
SBLs PR2-W1-WVR / 1-4.9v / 1-3 / 1-4 / 10mm
SBLs PR2-4.5V / 4.5v / 3 ONLY / ------ / 5mm
SBLs PR2-6V / 6v / 4 ONLY / ------ / 5mm
SMJLED / not stated / 2 ONLY / 2 ONLY / 5mm
SMJLED2 / not stated / 2 ONLY / ------ / 5mm
Tektite LPR-2 / 3v / 2 ONLY / ------ / 1 watt luxeon
Tektite LPR-3 / 4.5v / 3 ONLY / ------ / 1 watt luxeon
Tektite LPR-113 / 6v / 4 ONLY / ------ / 1 watt luxeon
Tektite LPR-10 / not stated / 2-6 / 2-6 / 10mm
LEDcorp Epieon 2 / 3v / 2 / ------ / 1 watt ?
LEDcorp Epieon 3 / 4.5v / 3 / ------ / 1 watt ?
LEDcorp Epieon 4 / 6v / 4 / ------ / 1 watt ?
Sino Union Night Pearl / 1,2,3 & 4 cell versions / 5mm
LEDtronics / 3v / 2 ONLY / ----- / 5mm
Nite-Ize / not stated / 2-6 / ----/ unknown
Terralux TLE-20 / 3-6v / 2-4 / ----/ unknown
BatteryStation / ----- / 2 only / ----/ 1 watt CREE
Nite-Ize 1wattPR/----/ 2-6 /----/???

Click to expand...

The Welcome Mat is also a great resource.

P60 drop-ins thread for those of you who would also like to upgrade your P60/P90 accepting lights.

(in progress)

Re: Maglite LED and incan mods, Overview

All of these will work in the appropriately sized C or D Mag (except the reverse polarity one)

https://www.candlepowerforums.com/threads/178595

Re: Maglite LED and incan mods, Overview

Nite-Ize 3 emitter drop in for Incan Minimag
- ~8-10L (estimated) output, long run time, all flood, no hot spot or throw beyond ~15-20 feet. White LED model has a blue-ish tint. Multi colors available. Very good close proximity, emergency back-up light.
- Sellers: target, wal-mart, Frys
- Information URL: http://www.niteize.com/productdetail.php?category_id=28&product_id=110

**edit** the white wall beam shot in the URL above shows a very intense hot spot. No such spot exists however. I think they used a very long shutter speed to capture the light in that pic.... it is very deceiving.

Re: Maglite LED and incan mods, Overview

So, are the Xenon bulbs less forgiving of overdriving than the Krypton bulbs?

Re: Maglite LED and incan mods, Overview

Yes. They are white and brighter because they are driven closer to the edge then the normal ones.

Re: Maglite LED and incan mods, Overview

I was hoping to convince someone to create a definitive resource for all new users who continually ask the perennial question "What can I do to make my old 3D Maglite better?" This and similar questions regarding quick cheap upgrades to old Maglites are so common and pervasive on these forums that I'd like to see a permanent sticky addressing it established

One of the most inexpensive upgrades anyone can do for C and D Maglites is to replace the low quality plastic lens with a high transparency coated glass one called UCL (Ultra Clear Lens). It can allow up to 10% more light to pass through! The glass is so clear that it appears, sometimes, that the Maglite has no lens at all! Both the C and D size Mag's use the same size lens - 52.1mm x 1.90mm. One source to obtain them is at flashlightlens.com on this page. Cost is only $6.25 and is well worth it :thumbsup:

Re: Maglite LED and incan mods, Overview

Yeah thanks for this post, it answers all my "beginners" questions. It's getting me started on four projects, then I can get to bigger and better stuff.

Re: Maglite LED and incan mods, Overview

Great idea this thread. Thanks for doing this.

Here's a link to my tutorial for anyone looking to upgrade a 2D (or 2C) Mag to a SSC P4 LED using a micropuck driver. Suitable DIY project if you have a soldering iron and a few basic tools.

[Any questions, please post in the thread. I don't mind the odd PM from people with questions, but I don't always have the time to respond, also sometimes the questions could be answered by others on the forum.].

Cheers

Re: Maglite LED and incan mods, Overview

Great thread! :twothumbs


Should be a sticky.

Re: Maglite LED and incan mods, Overview

Stress_Test said:

So, are the Xenon bulbs less forgiving of overdriving than the Krypton bulbs?

Click to expand...

I am running a 3 cell MagNum Star (Xenon) off 4x AA NiMH no problems so far.

Re: Maglite LED and incan mods, Overview

But remember NiMh batteries have lower voltage then alkaline batteries. 1.2v vs 1.5v. That is probably why the bulb didn't pop.

Re: Maglite LED and incan mods, Overview

The Philips 5761 is a good mod for the MagCharger.

Re: Maglite LED and incan mods, Overview

I don't have anything to add for the moment (will have to look through my mag mods) but this should really be made a sticky.

I've read/seen basically the same question (how do I mod my AA/C/D mag) repeated about 5 times a week. Amazing how no one searches, but also, the information is all over the place, so centralizing it would be a great idea.

:candle:

Re: Maglite LED and incan mods, Overview

Are there any threads that show step-by-step mods for the minimag LEDs? Like emitter changes for more output.

Re: Maglite LED and incan mods, Overview

I remember seeing at least one but I can't find it right now.

Re: Maglite LED and incan mods, Overview

Here is the april Fool's Malkoff Minimag Drop In thread

https://www.candlepowerforums.com/threads/193863

Re: Maglite LED and incan mods, Overview

Cool thread, Gunner12. It'll make a lovely link in the Welcome Mat. :thumbsup:

I have five Minimags and ten Mags, and only ONE of those is a bone stock incan.

Incan:

There are lots of good bulbs to use. Look for products from Osram, Philips, GE, Sylvania, and Welch-Allyn. These are only a few manufacturers out of many, so keep on the lookout.

Try www.bulbconnection.com. They carry lots of bulbs, and have at least some specs on most of them. They also have a great search function.

BTW, I'm using a 5-cell Mag-Num Star (xenon) with a pair of Li-Ions, and it works fine.

Most high-powered incan mods will need an aluminum reflector (available from CPFer fivemega or www.kaidomain.com) and glass window (available from www.flashlightlens.com or www.kaidomain.com). Bulbs above 30-35W or so are likely to melt the stock plastic components.

Few bulbs have a standard PR base (the ROP bulb being an exception). The most common base for high-powered incans is a bi-pin, as seen in the stock incan Minimag. Of course, these are much more powerful, so you can't just drop them into a little plastic socket. There are two main options: get a PR>bi-pin adapter, or replace the entire bulb socket. You can get an adapter from fivemega or www.kaidomain.com. The second option, replacing the entire socket, requires more work, but is usually cheaper and more effective. The solution I use is CPFer kiu's "high-temp socket."

Ordinary alkaline batteries are pretty much out for most incan mods. The most popular solution is using NiMH AAs, either in an adapter or permanently assembled into a pack. For adapters, look for fivemega's or modamag's work. For custom-made battery packs, contact CPFer LuxLuthor or try www.cheapbatterypacks.com. The advantages of an adapter are that you can remove the cells from it and charge them individually, while a pack may be easier to handle and capable of higher current.

If you want to pack four AAs side-by-side, you'll generally need to bore out your Mag (for a greater inside diameter). Boring is also necessary for 2/3A cells (see www.cheapbatterypacks.com for more info on this size and other cells).

One bulb I'm using is the hundred-watt Osram 62138, which is used in the USL. The USL is a 2D Mag holding 11 high-current AA NiMHs, with a few thousand lumens of output. My version uses 12 weaker AA NiMHs in a 4D (with an LM317T-powered LED sticking out of the tailcap for a low mode). The 62138 is a very nice bulb, but there many others.

Remember, incan mods can pack some serious power, so please be careful.

LED:

The main issue with LED Magmods is the heat. The heat produced by an emitter (or emitters) must be moved away from it somehow, and that task is very difficult in the stock Mag bulb post. Even Mag's own MagLED has built-in thermal throttling, which decreases power as the unit heats up in order to prevent it from being damaged by the heat. For this reason, high-power LED mods generally pack a heatsink into the entire width of the Mag tube, to transfer heat from the emitter(s) to the heatsink, then to the Mag's body and into the surrounding environment.

To make your own custom mod, look for a heatsink from CPFers H22A, modamag (modamag's work is available at the Sandwich Shoppe), or others. These allow you to choose your own emitter(s) and driver(s) for a personalized touch.

One driver I've found handy for LED Magmods is the LM317T, available at RadioShack and www.kelvin.com, among other places. It allows you to power your emitter(s) with constant current, determined by a resistor or pot. Examples are the Birthday Mag (link, link) and EZ-Dim (link). This driver is cheap and easy to use, but is less efficient than many other drivers.

Another method to control the output of your LED Magmod is a simple resistor. Use a resistor calculator to determine what value(s) to use.

Minimags:

There aren't too many mods available for the Minimag. Most focus less on raw power and more on practicality. They generally have a bi-pin base (like the stock incan Minimag bulb) and an emitter, with a driver in the middle. Another old LED drop-in is the Opalec Newbeam. To my knowledge, there are no incan mods for the Minimag more powerful than the Auroralite hotwire kit.

...Yet. :devil:

Re: Maglite LED and incan mods, Overview

Gene from Malkoff has hinted that he has played around with a few minimag samples. I think everyone should express their voice to him in wanting one.

.............This is not part of the April Fool's joke either

Deleted info as it's now in the first post.

:bump: