Coherence
Newly Enlightened
2 AA Maglight -> Luxeon Star (LS) conversion.
Somebody had to do it, so I gave it a try.
I borrowed a digital camera from work, and took a 'test' set of pictures. I say test because the flash went off on EVERY photo and I didn't think some pictures would come out right. But I am using them anyway, here is the Photo Album. The first three pictures are of a Matrix headlamp conversion I rambled on about in this thread.
Here is how to do it:
Take off the head of the 2 AA minimag. Take apart the head of the mag by removing the lens and reflector. Remove the lens from the LS. Trim off the clear plastic tab on the LS lens and drop it into the head. Perfect fit, right? In the end I added a thin o-ring between the LS lens and the mag lens to keep it secure and prevent any rattling (see photo 4).
Now you have to separate the LED from the circuit board. Slip a knife between the board and the lens holder, pry just until the glue breaks on each side where there is glue. Put a soldering iron tip on each solder pad next to the LED and work it free. Separate the LED from the lens holder.
Next I built a 'base' for the LED. Just a metal washer, outside diameter just smaller than the threaded portion of the inside of the head. You want to have the washer behind the LED as close as you can to it. I just used epoxy to attach the two (AFTER doing the soldering described below).
Run the LED for a bit and feel which lead is giving off the most heat, solder that one to the washer. Solder a lead of stiff wire to the other LED terminal and bend it such that it points straight down in the middle of the washer (directly away from the LED). Solder another lead to the washer and point it the same way. These are the wires to stick into the bulb socket on the mag.
Go ahead and test it, remember that polarity matters.
To reassemble the light, put the head on without any lenses, screw it down all the way. Insert the new lamp module, then place the LS lens on top. Now unscrew the head until it comes up to meet the LS lens. Stop. The lens should not press down on the LED or it turns off the switch on the minimag. Place the new o-ring and mag light lens over the LS lens and replace the head cover.
It should light when you add batteries. I finished it by using heat conducting grease (called heat sink compound at Radio Shack) between the washer and head and permanently gluing the mag switch to stay on, and gluing the head so you cannot twist it. As far as I know it is waterproof too (haven't tested though).
The final touch is to add a tailcap switch for positive on/off click action.
Somebody had to do it, so I gave it a try.
I borrowed a digital camera from work, and took a 'test' set of pictures. I say test because the flash went off on EVERY photo and I didn't think some pictures would come out right. But I am using them anyway, here is the Photo Album. The first three pictures are of a Matrix headlamp conversion I rambled on about in this thread.
Here is how to do it:
Take off the head of the 2 AA minimag. Take apart the head of the mag by removing the lens and reflector. Remove the lens from the LS. Trim off the clear plastic tab on the LS lens and drop it into the head. Perfect fit, right? In the end I added a thin o-ring between the LS lens and the mag lens to keep it secure and prevent any rattling (see photo 4).
Now you have to separate the LED from the circuit board. Slip a knife between the board and the lens holder, pry just until the glue breaks on each side where there is glue. Put a soldering iron tip on each solder pad next to the LED and work it free. Separate the LED from the lens holder.
Next I built a 'base' for the LED. Just a metal washer, outside diameter just smaller than the threaded portion of the inside of the head. You want to have the washer behind the LED as close as you can to it. I just used epoxy to attach the two (AFTER doing the soldering described below).
Run the LED for a bit and feel which lead is giving off the most heat, solder that one to the washer. Solder a lead of stiff wire to the other LED terminal and bend it such that it points straight down in the middle of the washer (directly away from the LED). Solder another lead to the washer and point it the same way. These are the wires to stick into the bulb socket on the mag.
Go ahead and test it, remember that polarity matters.
To reassemble the light, put the head on without any lenses, screw it down all the way. Insert the new lamp module, then place the LS lens on top. Now unscrew the head until it comes up to meet the LS lens. Stop. The lens should not press down on the LED or it turns off the switch on the minimag. Place the new o-ring and mag light lens over the LS lens and replace the head cover.
It should light when you add batteries. I finished it by using heat conducting grease (called heat sink compound at Radio Shack) between the washer and head and permanently gluing the mag switch to stay on, and gluing the head so you cannot twist it. As far as I know it is waterproof too (haven't tested though).
The final touch is to add a tailcap switch for positive on/off click action.
