35W mag HID build?

nickz

Enlightened
Joined
Dec 30, 2005
Messages
267
Location
Illinois
Something I have been wanting to do for a year or so is put together a 35 Watt HID in a mag body. I am curious if anyone else here has attempted the same and if so can point me in the right direction for the build. What I am curious about is buying a quality ballast that is still small enough to fit in the mag body.

My options I have thought about so far is to machine myself a large mag head similar to Fivemega's and leave room for a ballast there but I worry about the small amount of heat the ballast would receive. The second option I have thought about is using a longer mag body such as a 4D and using a portion of the upper or lower tube to install the ballast there.

Can anyone recommend a good starting kit? Maybe something that was designed for automotive use but can be retrofitted to the mag body. I have no problem machining anything I need, but i would like to make it appear to be a stock mag lite if possible. I am hoping someone here has went down this road and is willing to share some insight.

I am open to recommendations for smaller 10W, 24W, etc. Of course I would love to drive a 50W in the mag setup but I am not sure how easy that would be. In the end I would prefer to not end up with a "frankenlite". As said, I would like for it to appear as a standard mag lite in anything from 4D size lite down to even a cutdown 1D lite.

Thanks in advance for any help. It is appreciated as HID parts can be expensive when you start screwing up the build with parts that just will not work out.
 
I guess a few people have tried this, or started to try this. Getting the 18650's in there is possible if you can machine the tube. 14500's will also fit in a triangle, again if you can machine the inside.

But the ballast is going to be a pain. I hacked up an automotive ballast to see if they could be adapted... by relocating the ignitor, it is probably possible, but not exactly easy. If you can afford it and can source it, your best bet is to buy a cylindrical ballast, like in the thread already mentioned.
 
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