Here is a Mag XM-L mod that was pretty straight-forward. The main goal of the project was bang for the buck. I hope this mini-guide will be helpful to others as I myself have learned a lot from others here on CPF; just my way of contributing back to the forums.
Mag 2D Gray (Incan version)
Cree XM-L T6 1D tint on 14mm round board
H22A Flattop Bare Heatsink
Shiningbeam 2.8A 3-Mode PWM Linear Regulator Driver (8 X AMC7135)
20 AWG Silver coated Teflon jacket wire
3 x C Accupower 4500mAh NiMH LSD Batteries
52.1mm Hardcoat Acrylic Lens
The first pic shows 20 gauge Teflon wire soldered to the emitter board. I then attached the emitter board to the heatsink with Arctic Alumina thermal epoxy. The emitter wires were then bent into shape for preparation for the driver as seen in the next set of pictures.
The battery wires were then soldered to the driver as well as selecting the desired mode (3-mode) by bridging the correct star to the outer ground connection. The emitter wires were then soldered to the driver. I then attached an anodized Akasa BGA ram heatsink to the LED side of the driver with Fujik thermal glue. The main purpose of the BGA heatsink is to prevent any possible shorting of the driver on the main heatsink.
The stock switch was then modified (cam cut off) and the battery wires from the driver were soldered to the switch. The switch assembly was then placed back inside the battery tube and the snap ring was reinstalled. Ceramique thermal paste was then used on the inside of the battery tube and on the heatsink accordingly.
The heatsink was then pushed into the battery tube and any excess thermal paste cleaned off. Also pictured is the modified stock reflector with the focusing cam cut off. The best focus was obtained when the top of the emitter pedestal base was at the same level as the bottom of the reflector lip.
The use of 3 C cells in a 2-D host requires a battery sleeve (1 inch ID/1.25”OD PVC pipe). The tailcap spring was cut down and the anodizing was removed from the inside of the tailcap with Drano Max Gel.
Beamshots will follow shortly…