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Thread: Boring service for Surefire® and other aluminum or titanium lights

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


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



    Surefire WML bored for 18mm cell


    Surefire C2 bored for 18650 + custom machined spacer for CR123 cells

    This machining service provides bore, ream & hone your Fury/6P/C2/M2/C3/M3/U2/M4 & Weapon Lights to accept the AW18650, Panasonic protected 3400 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 ball honing tools. 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. Final inside bore diameter is 18.90mm & will accommodate every current 18650 cell made today.

    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 larger in diameter than any prior AW cell & cannot be used 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.

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

    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. Some heads will unscrew & others will not no matter what. Using excessive torque/heat/etc. will destroy the light. 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 gunsmithing, 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/Z2/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.

    *
    Every recent X-Series light has required boring with the head attached & cost is 50% more than shown above. The Fury P2X is $63 & the P3X is $78

    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 & cost more. Unlike any other lights a WML may require as many as three separate custom fixtures, three setups, etc.
    One cell WML's are $57 + shipping.
    Two cell WML's are $67 + shipping.
    Three cell WML's are $77 + 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. I believe this is the best way to preserve the unique tail profile & standard rates apply (see above). On Elzetta please send complete light so I can verify function after machining is done.


    Custom titanium lights: single cell lights like the Ti McClickie Pak (1xCR123), Mac's EDC, etc. are $150. Other custom lights priced on request.

    V10R Ti:
    Boring the body
    for either 17mm or 18 mm cells is $63.
    Boring the extender
    is $32 for either 17mm or 18mm cells. Removing the hex & matching diameter to body is $22. Grooving the outside to match the body is $15.

    Battery sizes 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" (18.8mm)
    Please keep this in mind when having your E-series bored for 18650. Those bores will not accept the 3400 mAh cells.
    Domestic shipping choices are USPS (primarily by Priority Mail), Federal Express & United Parcel Service. Insurance is recommended. International shipping choices are USPS, Federal Express & United Parcel Service. Insurance is recommended especially on international shipments.

    USPS domestic & international rate & service calculator: http://ircalc.usps.gov/

    FEDEX rate calculator: https://www.fedex.com/ratefinder/home

    UPS
    shipping to the United States: http://www.ups.com/content/us/en/shi...?WT.svl=SubNav

    UPS
    international shipping: http://www.ups.com/content/us/en/shi...?WT.svl=SubNav

    These are the only shipping options offered. If none of these services is satisfactory please don't send your light for machine work.
    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).

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

    SureFire, LLC, which manufactures and sells Surefire® 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 Surefire® trademark is strictly for the purpose of identifying the host flashlight for the Precision Works modifications.
    Last edited by precisionworks; 06-11-2014 at 09:40 AM. Reason: repriced WML's
    Surefire® boring including E-Series & Weapon Lights, gun repairs, blueing & custom work * PM's disabled * Please Email & PayPal through Precision-Gunsmithing.com

  2. #2
    *Flashaholic* precisionworks's Avatar
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    Default Re: Boring service for Surefire® 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 06:12 PM.
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    *Flashaholic* precisionworks's Avatar
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    Exclamation Re: Boring service for Surefire® 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.
    Surefire® boring including E-Series & Weapon Lights, gun repairs, blueing & custom work * PM's disabled * Please Email & PayPal through Precision-Gunsmithing.com

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    *Flashaholic* precisionworks's Avatar
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    Default Re: Boring service for Surefire® 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 & ready for reaming:



    Finished with 18650 fully seated:



    Family photo:

    Surefire® boring including E-Series & Weapon Lights, gun repairs, blueing & custom work * PM's disabled * Please Email & PayPal through Precision-Gunsmithing.com

  5. #5

    Default Re: Boring service for Surefire® 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 Surefire® 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
    Surefire® boring including E-Series & Weapon Lights, gun repairs, blueing & custom work * PM's disabled * Please Email & PayPal through Precision-Gunsmithing.com

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    Flashaholic* smarkum's Avatar
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    Default Re: Boring service for Surefire® and other aluminum or titanium lights

    I love this thread. . . nice to see it starting fresh. Will make searching through it much easier!
    I love your pics and descriptions. I have NO idea about milling or any of the mechanical processes you discuss, but I very much enjoy the reading and learning that does come from your descriptive posts! Keep up the great work Barry!
    "I always prefer to believe the best of everybody it saves so much time." - Rudyard Kipling

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    Flashaholic OneBigDay's Avatar
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    Default Re: Boring service for Surefire® and other aluminum or titanium lights

    I just found this subforum. Somebody suggested in the V10R Ti+ thread that precisionworks could bore the AA Extender tubes for the V10R Ti to fit a 17500 cell. Is this a service you offer and if so what would it cost?

    Also interested in having the "hex" shape ground down to just a simple cylinder that matches the diameter of the rest of the light. This is more of an optional wish but depending on the price I might go for it.

    I can't tell whether this forum or an email to the address in OP in the preferred way to ask a question like this. TIA for any replies or suggestions.

  9. #9
    *Flashaholic* precisionworks's Avatar
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    Default Re: Boring service for Surefire® and other aluminum or titanium lights

    Quote Originally Posted by OneBigDay View Post
    I just found this subforum. Somebody suggested in the V10R Ti+ thread that precisionworks could bore the AA Extender tubes for the V10R Ti to fit a 17500 cell. Is this a service you offer and if so what would it cost?
    If there's enough wall thickness in the AA Extender it could be bored for 17mm. I'd be glad to measure it if you'd send it in.


    Boring the extender for 17mm is $20. Turning down the outside to remove the hex & remove the Ti.AA.EXT. marking is $20. Machining three grooves in the smoothed off extender is $10.

    can't tell whether this forum or an email to the address in OP in the preferred way to ask a question like this.
    Either one is fine.
    Last edited by precisionworks; 04-17-2012 at 08:19 PM.
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    *Flashaholic* precisionworks's Avatar
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    Default Re: Boring service for Surefire® and other aluminum or titanium lights

    Quote Originally Posted by Doc View Post
    E-mail sent for Lens Light mini trits! Doc.
    Doc, I'm moving your post to the other thread titled Tritium Slot machining & installation
    Surefire® boring including E-Series & Weapon Lights, gun repairs, blueing & custom work * PM's disabled * Please Email & PayPal through Precision-Gunsmithing.com

  11. #11

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

    Quote Originally Posted by precisionworks View Post

    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
    Wow, 1200 grit!

  12. #12
    nfetterly's Avatar
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    Default Re: Boring service for Surefire® 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.


  13. #13
    *Flashaholic* precisionworks's Avatar
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    Default Re: Boring service for Surefire® 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 04:46 PM.
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    *Flashaholic* precisionworks's Avatar
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    Default Re: Boring service for Surefire® 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 02:44 AM.
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    Default Re: Boring service for Surefire® and other aluminum or titanium lights

    SWEET!!!

    I Have an XML drop in waiting for this baby!

  16. #16
    *Flashaholic* precisionworks's Avatar
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    Default Re: Boring service for Surefire® 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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  17. #17

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

    Quote Originally Posted by precisionworks View Post
    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.
    Maybe it's a gift from an appreciative customer.

  18. #18
    *Flashaholic* precisionworks's Avatar
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    Default Re: Boring service for Surefire® and other aluminum or titanium lights

    Quote Originally Posted by ExZeRoEx View Post
    Maybe it's a gift from an appreciative customer.
    LOL

    Even more unusual is the McGizmo that was purchased by a member in China from a member in the USA - who shipped it to me for tail trits. I've send emails indicating that the light is done & that I will ship it as soon as payment is received for the trit work but no response.

    Now that would be a nice gift

    EDIT - figured this out by going back through my paypal statements & matching purchases with payments by members.
    Last edited by precisionworks; 04-18-2012 at 06:40 AM.
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    *Flashaholic* precisionworks's Avatar
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    Default Re: Boring service for Surefire® and other aluminum or titanium lights

    Just a note about 18650 batteries ...

    For quite some time the AW18650 2900 mAh has been the battery most often used in the lights I've bored. AW now offers an 18650 3100 mAh (red top). Most of you already know this but the reason for posting is to mention that the 3100 is somewhat smaller in diameter than the 2900.

    Either battery works well in a full sized light that is final bored to 0.738" (18.75mm). The 3100 is a better choice for the small tube lights like the E-series which are minimum bored to 0.728" (18.5mm). The 3100 cells that I've measured run fully .002"-.003" (.05-.07mm) smaller than the 2900's and slide more easily into the minimum bored lights.

    Both the 3100's & the 2900's will fit into the E-series. The 2900 is a snug fit & the 3100 is a more perfect fit. Other brands may or may not fit into the minimum bored E-series so please send a battery or two with any light you want to have bored.

    Will the super fat batteries fit into a standard bored light ?

    There are a least two brands (RediLast & UltraFire) that run larger in diameter than the AW cells. No one has yet mentioned any issues with using the fatter cells in a standard bored light. Again, sending along a battery or two guarantees that your cells will work properly. I can bore and ream to 0.750" (19.0mm) if you want that done - please include a note with your light or lights stating that you want the larger bore. There's no extra charge for the larger diameter boring.



    EDIT: Every light that was on the bench is now bored. Waiting on two pay pal payments so those can ship out. Trit slot milling will start later today & I appreciate everyone being so patient while waiting for their lights to be finished.
    Last edited by precisionworks; 04-19-2012 at 07:46 AM.
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  20. #20
    Flashaholic* F250XLT's Avatar
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    Default Re: Boring service for Surefire® and other aluminum or titanium lights

    Might be sending you a C2 soon...
    "I am not a Collector" - Tim

  21. #21
    Flashaholic* Henk_Lu's Avatar
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    Default Re: Boring service for Surefire® and other aluminum or titanium lights

    wrong thread, sorry...
    Last edited by Henk_Lu; 06-02-2012 at 12:37 PM. Reason: big mistake!
    My way : From Maglite and drop-ins over Fenix & Co to the real things - Customs and Titaniums!

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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?

  23. #23
    *Flashaholic* precisionworks's Avatar
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    Default Re: Boring service for Surefire® 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.

  25. #25
    *Flashaholic* precisionworks's Avatar
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    Default Re: Boring service for Surefire® 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 Surefire® 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.

  27. #27
    *Flashaholic* precisionworks's Avatar
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    Default Re: Boring service for Surefire® 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 Surefire® 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 08:05 AM.

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    Flashaholic* tobrien's Avatar
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    Default Re: Boring service for Surefire® and other aluminum or titanium lights

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

    is missing an 'm' when you click on the URL.

    also I'm about to hit y'all up through the precisionworks.com page

    thank you!
    aka Edgar Allan Bro, Brosama Bin Liftin, Walter Crunkite, Bro Namath, Teddy Brosevelt, and the Tomahawk Crunkmissile.
    my lights - review of PrecisionWorks - that's Gucci Mane in my avatar

  30. #30
    *Flashaholic* precisionworks's Avatar
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    Default Re: Boring service for Surefire® and other aluminum or titanium lights

    Quote Originally Posted by tobrien View Post
    the precisionworks link "PM's are disabled so please click on the "contact" page at www.PrecisionWorks"

    is missing an 'm' when you click on the URL.

    also I'm about to hit y'all up through the precisionworks.com page

    thank you!
    Thanks for the heads up. I'll contact the site admin & have it corrected.
    Surefire® boring including E-Series & Weapon Lights, gun repairs, blueing & custom work * PM's disabled * Please Email & PayPal through Precision-Gunsmithing.com

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