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Thread: new set screw tool for Mag D switch

  1. #1

    Default new set screw tool for Mag D switch

    I just purchased a brand new Mag 6D and went to swap out the switch with an AW 3 level driver. Could not get the stock switch out because the set screw is no longer turned with a 2mm allen wrench. I called Maglite and the person I spoke with confirmed this but could not tell me what exactly the needed tool is or its size since it's "so new". Anybody know what kind and size tool is now required for the set screw?

  2. #2
    Flashaholic* mrartillery's Avatar
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    Default Re: new set screw tool for Mag D switch

    I always use a 5/64 allen, comes out every time.

  3. #3

    Default Re: new set screw tool for Mag D switch

    The person I spoke to at Maglite said it no longer is an allen wrench, but could not tell me just what it is now. I'm thinking a star wrench, but I don't have any that small. I guess I might pick up a set and see.

  4. #4
    Flashaholic* mrartillery's Avatar
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    Default Re: new set screw tool for Mag D switch

    That's odd, I haven't ran across one of these yet, I've got several of the new design without the spring on the bottom but none yet that won't accept allen wrenches.

  5. #5

    Default Re: new set screw tool for Mag D switch

    Take a flashlight and look down the switch stem to see what's in there. I can see the outline of an Allen head in my various D Mag switches.

  6. #6

    Default Re: new set screw tool for Mag D switch

    I ran into this too on a recently purchased 2D. I haven't figgured it out yet, but if I had to guess I'd be looking at torx. I have some hobby size torx if I can find them. I'll report back.
    RJ

  7. #7
    Flashaholic*
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    Default Re: new set screw tool for Mag D switch

    Nothing that I have (yet) will work . It looks to me like it is a Torx security screw, approx 0.65, my small 0.70 will not fit down the switch.
    Great spirits have always encountered violent opposition from mediocre minds.
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  8. #8
    Flashaholic* Aircraft800's Avatar
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    Default Re: new set screw tool for Mag D switch

    I had one that I believed the set screw was a reject, or damaged. I used a Bristol Wrench to get it out, pitched it in the trash, and installed the regular setscrew.

    Maybe it wasn't a screwed up one, maybe some lame attempt at security? Try a Bristol key, not sure of the size, I just got a small cheep kit at a flea market.

  9. #9
    *Flashaholic* LuxLuthor's Avatar
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    Default Re: new set screw tool for Mag D switch

    Quote Originally Posted by Aircraft800 View Post
    I had one that I believed the set screw was a reject, or damaged. I used a Bristol Wrench to get it out, pitched it in the trash, and installed the regular setscrew.

    Maybe it wasn't a screwed up one, maybe some lame attempt at security? Try a Bristol key, not sure of the size, I just got a small cheep kit at a flea market.
    Hard to imagine they would intentionall switch over to such an obscure Bristol set screw.

  10. #10
    Flashaholic*
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    Default Re: new set screw tool for Mag D switch

    Whan I tried to get a replacement mag switch from the UK supplier about a year ago now they said I would have to send it in as it required a special tool, I did mention the replacement switch kit came with an allen key so what was the deal, but they wouldnt have it...I had to send it in or no deal.

  11. #11
    Flashaholic 737mech's Avatar
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    Default Re: new set screw tool for Mag D switch

    I ran into this problem as well on a few new switches I bought from Zbattery. I have not looked into it to figure out the proper tool yet.

    edit, just confirmed that the new set screw is in fact a torx bit but not sure what size. The T6 I had was a bit to small and the T15 was a bit to big. Just for the record the sizes go like this T6, T7, T8, T9, T10, then it jumps to T15.
    Last edited by 737mech; 05-17-2010 at 01:20 AM.

  12. #12
    Flashaholic* Aircraft800's Avatar
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    Default Re: new set screw tool for Mag D switch

    So I'm not crazy, there is a new one! I wish I wouldn't have pitched it in the trash, and taken a closer look and a few pictures!

  13. #13

    Default Re: new set screw tool for Mag D switch

    If T6 is a bit too small, it must be T7 or T8. The smallest I have is T9 and it's too big. T7 is very similar in size to a 2mm allen, so it seems likely.

  14. #14
    Flashaholic Billy Ram's Avatar
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    Default Re: new set screw tool for Mag D switch

    All the replacement switches I've gotten came with a hex key. They don't include the hex or torx wrench any more
    Billy

  15. #15

    Default Re: new set screw tool for Mag D switch

    Not having a T7 wrench, I was able to remove the new set screw by using a 2 mm allen wrench altered by grinding and shaping a standard screw driver blade onto it. Since the set screw has a 6 armed star pattern, two arms are directly opposite one another, allowing a standard screw driver blade to span across. Not "the right tool for the right job", but it easily removed the set screw.

  16. #16
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    Default Re: new set screw tool for Mag D switch

    Well, I ordered a new Mag D switch of the UK supplier, and it has arrived with an allen key in the pack...Didn't check if the screw was a different type, but I assume not as the key was included, sealed in the package....Sometimes I love it when the UK is slower than the US, for things like torch latest models.

  17. #17
    Flashaholic* Techjunkie's Avatar
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    Default Re: new set screw tool for Mag D switch

    I thought I had a defect and pitched my screw into the trash too. What a pain in the butt that Mag is changing this. What could possibly be there motivation? Maybe to sell Mag branded, proprietary switch removal tools?

  18. #18
    Flashaholic* Techjunkie's Avatar
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    Default Re: new set screw tool for Mag D switch

    Turns out I still had it. Here's a crappy pic:



    That's a hole in the center, not a post, so a security bit probably isn't necessary, just a torx of the right size. I'll bring it with me to Ace hardware and see if a #7 fits. Even if it does, finding a #7 torx driver with a shaft narrower than the bit might be a challenge.
    Last edited by Techjunkie; 05-28-2010 at 01:10 PM.

  19. #19
    Flashaholic*
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    Default Re: new set screw tool for Mag D switch

    Have you ever concidered they may be changing it because of 'us'

  20. #20

    Default Re: new set screw tool for Mag D switch

    Quote Originally Posted by Raoul_Duke View Post
    Have you ever concidered they may be changing it because of 'us'
    People who buy Mag-Lites to modify are still buying Mag-Lites. I doubt they care all that much. It's probably got more to do with cost or reliability.

  21. #21
    Flashaholic* copperfox's Avatar
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    Default Re: new set screw tool for Mag D switch

    I tried to get my tool in there, but it didn't fit. Or to phrase it another way, the screw is recessed farther than my tool can reach. The tool is a Husky (home depot) 8-in-1 precision torx screwdriver with sizes T4-T10 and T15.


  22. #22
    Flashaholic 737mech's Avatar
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    Default Re: new set screw tool for Mag D switch

    Sears has jewelers type torx drivers that will work. I have a couple, just not the right size.

  23. #23
    Flashaholic* Aircraft800's Avatar
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    Default Re: new set screw tool for Mag D switch

    Are you sure that is a Torx? From your photo it looks like a Spline Key or a Bristol Wrench. I was able to remove mine with a spline wrench, but it was part of a incomplete set, and it's too small to have the size stamped on it, so I'm unsure of the size, something like a .048 or a .060

    Now I wish I didn't pitch it in the trash, I thought it was a defect.

  24. #24
    Enlightened
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    Default Re: new set screw tool for Mag D switch

    Better pic?

    The smallest spline we have at work is .111

  25. #25

    Default Re: new set screw tool for Mag D switch

    The photo Techjunkie posted is deceiving. From that photo you might think Bristol or spline wrench, but it is not. It's a star/torx.

  26. #26

    Default Re: new set screw tool for Mag D switch

    Ok, I finally got my maglite apart. The set screw in mine was a Torx T8.

  27. #27

    Default Re: new set screw tool for Mag D switch

    I very recently bought three D Mags -- two 2Ds and one 4D. The 4D uses the usual Allen head set screw. Both 2Ds appear to use this new Torx set screw since I can't get the switch out. I guess I'll have to get a long T8 torx wrench.

  28. #28
    Flashaholic* Techjunkie's Avatar
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    Default Re: new set screw tool for Mag D switch

    I have this one on the way from DX, but being that the shaft is fatter than the bit, I'm not sure it will pass through the hole in the switch. For $1.39, I'll gamble. I think I recall seeing a set of L-shaped torx wrenches on Amazon along with the hex/allen wrench sets. What I'd prefer is a T-handle torx T8 though (like the 2mm hex one I have for my mags now).

  29. #29
    Flashaholic* mrartillery's Avatar
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    Default Re: new set screw tool for Mag D switch

    Quote Originally Posted by Techjunkie View Post
    I have this one on the way from DX, but being that the shaft is fatter than the bit, I'm not sure it will pass through the hole in the switch. For $1.39, I'll gamble. I think I recall seeing a set of L-shaped torx wrenches on Amazon along with the hex/allen wrench sets. What I'd prefer is a T-handle torx T8 though (like the 2mm hex one I have for my mags now).
    Yeah, you may have to do some slight grinding on that to get it to go in. But at only a $1.40 you're not out much.

  30. #30

    Default Re: new set screw tool for Mag D switch

    Wiha Tools has lots of Torx drivers. I ordered item #36648, the long-reach T8 Torx wrench.

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