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Thread: Boring service for SurefireŽ and other aluminum or titanium lights

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  1. #1
    *Flashaholic* precisionworks's Avatar
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    Default Boring service for SurefireŽ and other aluminum or titanium lights

    This machining service provides bore, ream & hone your Fury/6P/C2/M2/C3/M3/U2/Z2/M4 & Weapon Lights to accept 18mm cells. Your light body is first bored to near net size (three to six boring passes), reamed twice to assure dead on straightness & triple honed for final finish. Final inside bore diameter is 18.90mm & will accommodate every current 18650 cell made today.

    The smaller tube L1/A2/E-series & Scout Lights can be bored for either a 17mm protected cell or for a standard size 18mm cell (like the AW2900 mAh or AW3100 mAh). There's no excess of material to work with so the small tube lights are minimum bored, meaning that the cell will just slip into the bore. The newer AW3400 mAh cells are larger in diameter than any prior AW cell & may not fit in the E-series ... AW2900/AW3100 are the best choice. Final inside bore diameter is 18.50mm & will fit many but not all 18650 cells - you'll need to sort through your cells for best fit. Cell length is important in L-series light & they require the shortest flat top cells in order to function.

    PM's are disabled so please click on the "contact" page at
    www.Precision.Works


    Final boring pass, bar run in reverse to eliminate deflection caused when machining titanium.



    Surefire M600 Scout LightŽ bored for 18mm cell (Please note - Scout Lights use Surefire E-series dimensions & may not work with some oversize cells like some 3400 mAh. Cells up through 3100 mAh are recommended.)


    Surefire C2 bored for 18650 + custom machined spacer for CR123 cells to reduce rattle.


    V10r Ti extender bored for 18mm + de-hexed + grooved.

    NOTE #1: most Surefire machining mods don't require the entire light. Please ship only the parts to be machined, usually just the bare body. Removal of the clip, O-rings, combat rings, etc. is greatly appreciated.

    Note #2: The newer X-Series from Surefire have thread locker sealant (glue) at the body to head joint. Their website offers this caution:
    The heads of some SureFire flashlights and WeaponLights are fixed in place and are not meant to be removed. If the head of your illumination tool cannot be unscrewed with moderate hands-only effort, then it is not meant to be removed.
    I can bore the X-Series lights with head attached but it is much more complex & time consuming & cost is 50% more than a normal (head removed) boring job. Full details in post #199.

    Note #3: My shop primarily provides trouble shooting, emergency repairs & fabrication. Flashlights are machined whenever the time is available, meaning that your light may not be machined for some weeks after arrival - lights may be here for 15-30 days & sometimes longer before they can be machined. Please don't send your light if you need it back by a date certain. Lights are machined in the order in which they arrive.

    Boring (with head removed)*:
    Two cell
    lights like the Fury P2X/6P/C2/M2/etc are $42 + shipping.*
    Three cell lights like the Fury P3X/9P/C3/M3 & any E-Series or L-Series lights are $52 + shipping.*
    Four cell lights like the M4 are $62 + shipping.

    *Recent X-Series light have required boring with the head attached & cost is 50% more than shown above. The Fury P2X is $63 & the P3X is $78. The Z2 is extraordinarily difficult to set up & machine so the cost is $84.
    Spacer to fit CR123 cells:
    $10 each or $15 for two to fit a 2-cell light
    $15 each or $25 for two to fit a 3-cell light
    $20 each or $35 for two to fit a 4-cell light

    Weapon Lights require a much longer set up & take more machine time. Pricing is based on how many parts have to be machined since some are 1-cell, some 2-cell & some are 2-cell + extender.
    One piece WML's are $63 + shipping.
    Two piece WML's are $94 + shipping.
    Three piece WML's are $119 + shipping.

    Elzetta 2-cell or 3-cell (including the Bravo & Charlie models) can be bored from the head end & stoping slightly short of the tail end - please see image in post #242. This is the best way to preserve the unique tail profile & standard rates apply. Please send complete light so I can verify function after machining is done.

    SWM V10R Ti, V10R Ti+, M11R Ti, etc. :
    Boring the body
    for either 17mm or 18 mm cells is $84.
    Boring the extender for either 17mm or 18mm cells, de-hex extender & diameter match to body - $45.
    Other SWM mods are listed under "Mechanical Modding Services"

    Custom titanium lights: single cell lights like the Ti McClickie Pak (1xCR123), Mac's EDC, etc. are $168. Other custom lights priced on request.

    Battery diameter & length vary widely.

    AW18650/2900 consistently measure .725"-.726"
    AW18650/3100 measure .722"-.723"
    Panasonic 18650/3100 button tops are .729"-.730"
    Panasonic 18650/3400 run very large, .738"-.740"

    Length runs anywhere from 65mm to 70mm (including the positive button if the cell is button top). L-series lights usually need the shortest possible flat top cell. When running 2x18650 you may need to run a button top at the tail end & a flat top at the head end.


    PAYMENT is not due until the work is completed. An invoice will be sent as soon as your work is done. PayPal payments are accepted in USD only. You may prefer to send a check or money order with you light & that is perfectly fine. You may also pay using Visa-Mastercard-Discover-American Express.

    LEO-MIL-FF-EMT - please provide proof of status for special pricing (as much as 15% off + 48 hour turn around for duty lights).

    Ž SUREFIRE is a registered trademark of SureFire, LLC, 18300 Mount Baldy Circle, Fountain Valley, CA 92708 USA

    SureFire, LLC, which manufactures and sells SurefireŽ flashlights is not associated in any way form or fashion with Precision Works. SureFire, LLC, does not sponsor, warrant, or endorse any Precision Works modifications. Modifications to Surefire flashlights will void the warranty. The use of the SurefireŽ trademark is strictly for the purpose of identifying the host flashlight for the Precision Works modifications.
    Last edited by precisionworks; 11-16-2014 at 07:41 AM. Reason: repriced WML's
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  2. #2
    *Flashaholic* precisionworks's Avatar
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    Default Re: Boring service for SurefireŽ and other aluminum or titanium lights

    Lots of members have followed the "Boring Thread" for almost a year. During that time it grew to 17 pages with almost 500 posts. Pretty hard for me to locate something among that many posts & almost impossible for others. Having this sub forum allows starting separate threads & better organizing each one. Over the next days & weeks "new" boring thread will have quite a bit of info transferred from the original thread.

    This should be a worthwhile improvement for everyone.
    Last edited by precisionworks; 03-15-2012 at 07:12 PM.
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    *Flashaholic* precisionworks's Avatar
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    Exclamation Re: Boring service for SurefireŽ and other aluminum or titanium lights

    Someone (me) typed the wrong email address on all the website pages

    The email is now correct so please re send any questions or communications that went into cyberspace.
    SurefireŽ boring including E-Series & Weapon Lights, gun repairs, blueing & custom work * PM's disabled * Please Email & PayPal through www:Precision.Works

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    *Flashaholic* precisionworks's Avatar
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    Default Re: Boring service for SurefireŽ and other aluminum or titanium lights

    Milky sent an LX2 that he'd modded with his MOAL magic. Nearly 600 lumens OTF on my shop built sphere

    The owner wanted to run 1x18650 so this job is similar to boring an E-series tube. The biggest difference is that the battery sits farther down in the E-tube while it's a bit closer to the head in the LX2.

    Preparing for surgery - digital readout, inside micrometer, 0.7283" (18.5mm) reamer:




    Bored with 18650 fully seated:



    Family photo:

    Last edited by precisionworks; 09-20-2014 at 09:53 AM.
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    Default Re: Boring service for SurefireŽ and other aluminum or titanium lights

    It's like a magical glow coming out of that shiny tube.

  6. #6
    *Flashaholic* precisionworks's Avatar
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    Default Re: Boring service for SurefireŽ and other aluminum or titanium lights

    Quote Originally Posted by ExZeRoEx View Post
    It's like a magical glow coming out of that shiny tube.
    A McG Sundrop is located just out of the frame in the upper right corner & provides the internal highlights. To reach that level of smoothness requires:

    1) boring to a final diameter around 0.720"-0.722" (18.3mm). Half a dozen passes are needed because the factory bore is so small & the boring bar is very large relative to bore diameter.

    2) reaming to 0.7283" (18.5mm). This improves the surface finish while producing a true cylindrical shape. Taper & ovality are almost always present after boring & the reamer removes these small defects.

    3) ball honing with 320 grit followed by 600 grit & finally 1200 grit. Honing enlarges the bore slightly & it finishes at 0.7288"-0.7291" (18.51-18.52mm). Surface smoothness is much improved over reaming.

    Overkill? Probably
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    Flashaholic Greenbean's Avatar
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    Default Re: Boring service for SurefireŽ and other aluminum or titanium lights

    Quote Originally Posted by precisionworks View Post
    Milky sent an LX2 that he'd modded with his MOAL magic. Nearly 600 lumens OTF on my shop built sphere

    The owner wanted to run 1x18650 so this job is similar to boring an E-series tube. The biggest difference is that the battery sits farther down in the E-tube while it's a bit closer to the head in the LX2.

    Preparing for surgery - digital readout, inside micrometer, 0.7283" (18.5mm) reamer:

    Finished with 18650 fully seated:

    Question, is the driver in the LX2 the same as in the Fury?
    Reason I ask is you bored a Fury and found the driver worked on one 18650,

    Can a stock LX2 run on one Li-Ion?

    I have a new LX2 and love the light but am seeking a much greater output but with a Li-Ion cell behind it.


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    *Flashaholic* precisionworks's Avatar
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    Default Re: Boring service for SurefireŽ and other aluminum or titanium lights

    Quote Originally Posted by Greenbean View Post
    Question, is the driver in the LX2 the same as in the Fury?

    Can a stock LX2 run on one Li-Ion?

    ... am seeking a much greater output but with a Li-Ion cell behind it.
    To the first question, I have no idea. Someone on CPF, probably one of the electron gurus like JustinCase, might know the answer.

    Your second question ties into the first. My unscientific guess is that it may, meaning that it also may not.

    Question #3 is the easiest to answer - you absolutely will not get more lumens out of 1x18650 compared to 2xCR123. If the LX2 driver is similar to the Fury the runtime in regulation may be significantly longer. Here's what this is based on using Fury numbers:

    Current draw on 2xCR123 = 1770 mA & 100% brightness (better to use percentages than lumens in this case)

    Current draw on 1x18650 = 1770 mA & 100% brightness.

    Which indicates that the Fury driver maintains a constant 1770 mA draw with either power source - no matter if it's as high as 6.3 volts or as low as 2.8 volts the driver keeps the voltage seen at the emitter constant & the current stays constant.

    To get more lumens requires a trip to the day spa & Milky (Scott) is high on everyone's list. Probably others here that can mod your light but Scott has BTDT many many times. FWIW more lumens means a higher drive level & shorter runtime but 1x18650 beats the heck out of 2xCR123 every day of the week.
    SurefireŽ boring including E-Series & Weapon Lights, gun repairs, blueing & custom work * PM's disabled * Please Email & PayPal through www:Precision.Works

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    nfetterly's Avatar
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    Default Re: Boring service for SurefireŽ and other aluminum or titanium lights

    Quote Originally Posted by precisionworks View Post
    The smaller tube L1/A2/E-series can be bored for either a 17mm protected cell or for a standard size 18mm cell (like the AW2900 mAh or AW3100 mAh).
    I may be missing something - I've got a couple of L1 based lights with Milky heads, being a single (CR123) cell light no advantage boring to 17mm - are you just referring to the A2 & longer e-series.

    Is L1 body capable of boring to 18mm?
    PD Piston - I have one from a PD-S with no trit slot. I'm presuming that you could put a trit slot in that one?

    I've got a couple of lights that arrived back at the office today from Matt (AOTH), so I'll basically have all my lights back (except for 2 at Tom / Torchlab / Titanium Engineering / Oveready) so I need to see what I'm going to send for trit slots & boring. If an L1 can be bored to take a 18350 I think I'm in. I can measure my 18350s (4 or 6?) and send the fattest one or two if that would help. I'm thinking of getting my Mac's Ti SST-50 EDC bored to 18mm for the 18350 (somewhere you previously quoted a price) & probably some trit slots.


  10. #10
    *Flashaholic* precisionworks's Avatar
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    Default Re: Boring service for SurefireŽ and other aluminum or titanium lights

    I've got a couple of L1 based lights with Milky heads, being a single (CR123) cell light no advantage boring to 17mm ...

    IMO the most practical bore diameter for either the L1 or the L2 is 17mm. The reason is that both lights have a very tiny O-ring groove at the switch end, but it is large enough for a 17mm "long bore" where the tube is bored straight through without stopping the boring tool.

    From the factory the tube contains a central divider:


    Boring removes the central divider and easily allows the use of a 17mm cell:




    Milky can confirm whether his L1 modded head can be re-modded for use with 18mm, but I know he can do this for the L2 head. The issue with 18mm in both the L1 & the L2 is the O-ring groove at the tail - the 18mm bore has to end before that reduced diameter section (orange line is the negative end of the battery):

    This "short bore" causes the positive end of the battery to interfere with full seating of the head. Milky then re-mods the head so that it works with the new battery location.

    PD Piston - I have one from a PD-S with no trit slot. I'm presuming that you could put a trit slot in that one?
    Certainly, not a problem. Here are the prices for slotting either an aluminum or brass piston:

    1.5x5mm slots are $12 each
    1.5x6mm slots are $15 each
    2x6mm slots are $22 each
    2x8mm slots are $26 each
    2x12mm slots are $30 each
    2x24mm slots are $36 each

    (Longer slots will not fit on a PD piston and are shown only for reference).

    If the piston is titanium please double the price shown above.

    I'm thinking of getting my Mac's Ti SST-50 EDC bored to 18mm for the 18350 (somewhere you previously quoted a price) & probably some trit slots.
    I'll be more than happy to mill all the trit slots you want but I'm no longer boring any custom titanium lights. The large risk far exceeds the small profit that is made. Someone else may do this for you & you may want to post a request in the Materials/Mechanical/Machining forum.
    Last edited by precisionworks; 04-15-2012 at 05:46 PM.
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    *Flashaholic* precisionworks's Avatar
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    Default Re: Boring service for SurefireŽ and other aluminum or titanium lights

    mikesantor


    03-15-2012



    Barry,
    How is the boring going with all the ti work you have been wrapped up in? Thanks.


    Mike, your light is done

    Surefire E1E bored for 18350 ...





    Battery tube is first bored to near net size & then reamed to 18.50mm (.7283"). Bore is then refined with a 300 grit ball hone, followed by 600 grit, and finished with 1200 grit. Honing opens up the bore to 18.52mm (.7290"). The 18mm test cells will just slide into the bore without binding but there is no wiggle room - this leaves the wall thickness as great as possible.
    Last edited by precisionworks; 11-13-2013 at 03:44 AM.
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    Default Re: Boring service for SurefireŽ and other aluminum or titanium lights

    SWEET!!!

    I Have an XML drop in waiting for this baby!

  13. #13
    *Flashaholic* precisionworks's Avatar
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    Default Re: Boring service for SurefireŽ and other aluminum or titanium lights

    I just found an E2E body that has no owner's information. The shipping envelope shows an eBay seller "outfittu.com"

    If this is your body please post here or send an email through my website. Just need to know who it belongs to and if you want it bored for 17mm or 18mm.
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    Default Re: Boring service for SurefireŽ and other aluminum or titanium lights

    Quote Originally Posted by precisionworks View Post


    Mike, your light is done

    Surefire E1E bored for 18350 ...





    Battery tube is first bored to near net size & then reamed to 18.50mm (.7283"). Bore is then refined with a 300 grit ball hone, followed by 600 grit, and finished with 1200 grit. Honing opens up the bore to 18.52mm (.7290"). The 18mm test cells will just slide into the bore without binding but there is no wiggle room - this leaves the wall thickness as great as possible.
    Hi, I have a project, can you do the above on my E1e body? How much??

    I want to have it bored for this setup:



    Thanks!
    -PSM

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    *Flashaholic* precisionworks's Avatar
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    Default Re: Boring service for SurefireŽ and other aluminum or titanium lights

    Quote Originally Posted by PoliceScannerMan View Post
    ... can you do the above on my E1e body? How much??
    Certainly, $48 for boring & $6 return shipping.
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    Flashaholic* BenChiew's Avatar
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    Default

    Can you bore out the latest Generation 6 standard L1 to take 17670 battery?

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    *Flashaholic* precisionworks's Avatar
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    Default Re: Boring service for SurefireŽ and other aluminum or titanium lights

    That's a good question. Can you describe how the Gen6 is different from prior L1 models? Here's some info posted in the "old" and now closed boring thread, perhaps that may help:

    SF L1 Digital LumaMax.

    When SF manufactures this model, they bore in from each end & leave a centralized partition (or tube divider) which works fine for 1XCR123 ... but doesn't allow using a 17670 or 2XCR123.






    The L1 got a special fixture machined so it could be secured in the lathe, then it was bored & honed:











    SF installs a brass sleeve at the tail end, similar to the stainless sleeve in a U2 except that the brass is dead soft & easy to bore through:






    The L1 is now ready for more power:


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    Flashaholic* BenChiew's Avatar
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    Default

    I am not sure what the internal differences are between the various generations. Would someone knowledgeable chime in please.

    I just wanted to know if I can bore my stock standard L1 from the Gen 6 Cree to take a higher capacity 17670 battery.
    Thanks.

  19. #19
    *Flashaholic* precisionworks's Avatar
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    Default Re: Boring service for SurefireŽ and other aluminum or titanium lights

    Quote Originally Posted by Benchiew View Post
    I just wanted to know if I can bore my stock standard L1 from the Gen 6 Cree to take a higher capacity 17670 battery.
    Found these images in an old For Sale thread in The Marketplace:

    L1 Gen6 on left L1 Gen5 on right



    If there's enough length left to accommodate a battery 67mm long then yes, it can be bored. IIRC the Gen5 & Gen4 are both the same "longer" length and the Gen6, Gen3 and Gen2 are all the same shorter length. But I do not know which one is shown in the prior images.
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    Default Re: Boring service for SurefireŽ and other aluminum or titanium lights

    The Gen6 L1 can accommodate a battery of about 48mm long after boring. An 18500 did not fit afterwards.

    I need to make arrangements to send you an M4 to be bored for 18650s. PM incoming.

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    *Flashaholic* precisionworks's Avatar
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    Default Re: Boring service for SurefireŽ and other aluminum or titanium lights

    Quote Originally Posted by PCC View Post
    The Gen6 L1 can accommodate a battery of about 48mm long after boring. An 18500 did not fit afterwards.
    That is great information to have, TYVM

    If I understand this correctly only the Gen4 & Gen5 have the length needed for 18500/17670.

    I need to make arrangements to send you an M4 to be bored for 18650s. PM incoming.
    A pair of 18650's and the Malkoff or Nailbender tower would be a really sick light
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    Default Re: Boring service for SurefireŽ and other aluminum or titanium lights

    Quote Originally Posted by precisionworks View Post
    A pair of 18650's and the Malkoff or Nailbender tower would be a really sick light
    That's the plan
    Last edited by PCC; 08-12-2012 at 09:05 AM.

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    *Flashaholic* PoliceScannerMan's Avatar
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    Quote Originally Posted by precisionworks View Post
    Thank your for your kind words. That's the first "short" Surefire that was ever bored in my shop.
    Oh yeah that's right!!!

    Is it ok for you if I ship this week?

    I will send PP when u recieve.

    Thanks!
    -PSM

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    *Flashaholic* precisionworks's Avatar
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    Default Re: Boring service for SurefireŽ and other aluminum or titanium lights

    Quote Originally Posted by PoliceScannerMan View Post

    Is it ok for you if I ship this week?
    Surely. Please wait to pay until the work is completed as there are quite a few in line ahead of you.
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    Default

    Sounds good Barry. I'll ship in the AM.

    -PSM

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    Default Re: Boring service for SurefireŽ and other aluminum or titanium lights

    Hi Barry, I just received a bored E2e from a member who had it done by you - I just wanted to say that I love your work!

  27. #27
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    Default Boring service for SurefireŽ and other aluminum or titanium lights

    Great job Barry, I'm very happy with my E1e.

    -PSM

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    *Flashaholic* precisionworks's Avatar
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    Default Re: Boring service for SurefireŽ and other aluminum or titanium lights

    Happy to hear that PSM

    I don't imagine there are many other lights that small with so many lumens output.
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  29. #29
    *Flashaholic* precisionworks's Avatar
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    Default Re: Boring service for SurefireŽ and other aluminum or titanium lights

    Finished up all the E-series plus one M3 and one 7Z. Going out of town, be back Friday afternoon & will email invoices to all owners. Changing tooling to work on V10R's starting next week.

    Nice to once again see the workbench ...
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    Default Re: Boring service for SurefireŽ and other aluminum or titanium lights

    Barry, pardon my laziness for not searching, can you bore Ti McClicky CR123 paks to 18m?
    -PSM

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