Boring service for Surefire® and other aluminum or titanium lights

[precisionworks]

This machining service provides bore, ream & hone your 6P/C2/M2/C3/M3/U2/Kroma/M4 (and most other models) to accept the AW18650 or similar diameter 18mm cell. 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. Honing is first done with 320 grit, then 600 grit & finished at 1200 grit. The final ball hone operation leaves a super smooth finish but it is not a mirror finish - for that you'll want to polish the bore with a metal polish like Flitz or Semichrome applied on a snug fitting paper towel.

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). 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 slightly larger in diameter than any prior AW cell & cannot be used in the E-series.

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

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

NOTE #2: all standard machining mods are listed in this post. I'll be happy to look at any idea you have & quote a price. Please understand that custom mods often cost much more than standard mods.

Note #3: My shop primarily provides trouble shooting, emergency repairs & fabrication to local area business owners. Flashlights are machined whenever the time is available, meaning that your light may not be machined for many weeks after arrival - some lights may wait here for 60 to 90 days 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:

Two cell lights like the 6P/C2/M2/Z2/A2/E2 and small one cell lights like the L1/3P/E1 bored to 17mm are $42 + shipping. This includes the U2/Kroma basic service, please see below.

Three cell lights like the 9P/C3/M3 are $50 + shipping. Also the E-series & L-series lights bored to 18mm.

Four cell lights, like the M4, are $59 + shipping. Boring a U2/Kroma for rear battery loading is also $56.

SF A19 extender is $12 when bored with a light or $22 if bored by itself.

LEO-MIL-FF-EMT - please provide proof of status for special pricing.

V10R Ti:

Boring the body for either 17mm or 18 mm cells is $63.

Boring the extender is $22 for either 17mm or 18mm cells. Removing the hex & lettering is $22 & grooving the outside to match the body is $15.

Battery sizes vary widely. AW18650/2900 consistently measure .725"-.726" (18.4mm). AW18650/3100 measure .722"-.723" (18.3mm). Panasonic 18650/3100 button tops are .729"-.730" (18.55mm). Panasonic 18650/3400 run very large, .738"-.740" (18.8mm). Please keep this in mind when having your E-series bored for 18650. Those bores finish out at 18.5mm & I cannot go any larger than that.

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.

[precisionworks]

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.

[precisionworks]

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.

[precisionworks]

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 & ready for reaming:



Finished with 18650 fully seated:



Family photo:

[ExZeRoEx]

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

[precisionworks]

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

[Greenbean]

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.

[precisionworks]

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.

[nfetterly]

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.

[precisionworks]

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.

[precisionworks]

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.

[mikesantor]

SWEET!!!

I Have an XML drop in waiting for this baby!

[precisionworks]

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.

[PoliceScannerMan]

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!

[precisionworks]

... can you do the above on my E1e body? How much??

Certainly, $48 for boring & $6 return shipping.

[Benchiew]

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

[precisionworks]

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:

[Benchiew]

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.

[precisionworks]

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.

[PCC]

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.

[precisionworks]

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

[PCC]

A pair of 18650's and the Malkoff or Nailbender tower would be a really sick light

That's the plan

[PoliceScannerMan]

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!

[precisionworks]

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.

[PoliceScannerMan]

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

[samuraishot]

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!

[PoliceScannerMan]

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

[precisionworks]

Happy to hear that PSM

I don't imagine there are many other lights that small with so many lumens output.

[precisionworks]

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 ...

[PoliceScannerMan]

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