Apparent change in D Mag switch housing

[Justin Case]

I bought a spare D Mag switch from flashlightking.com recently to build an extra "drop-in" JimmyM-regulator/Kiu-socket D Mag switch. But instead of the usual D Mag switch, this is what my switch looks like on the bottom:

Here is what the bottom of the usual D Mag switch looks like:

Edit: I also notice that the switch barrel is different. The barrel is keyed. Unfortunately, I didn't have a non-keyed switch barrel to test if it works or not in this new switch housing.

This is a non-keyed switch barrel and housing from another D Mag switch:

 

[Robin24k]

Yup, my 3D is like that too. Looks like it might have a little bit less resistance.

 

[Fulgeo]

I purchased a 3D LED Mag light yesterday and the switch was of this variety. This is the first LED Mag host I have purchased. I purchased it over an incandescent host because I wanted to play with the new switch design and also compare the new reflector profile properties with the old design. Justin Case does the tower of your switch assembly look a bit shorter/different i.e. of the LED variety? I am curious if all the new D Mags will be this design or is it the LED variety only. Also hard to tell because the incandescent Mags commonly available could be all old stock.

 

[Justin Case]

The switch housing design change requires some minor mod'ing of the JimmyM/Kiu/D Mag switch bottom to make contact to flat top cells like AW's IMR26500s. After running the long pass through wire from the Kiu socket to the bottom of the Mag switch, you can solder the wire directly to the Mag's Batt+ contact and build up a solder bump to achieve contact to the IMR26500. Or you could solder a spacer. Or you could solder a short spring (e.g., scavenged from the PR bulb's spring).

 

[Justin Case]

I purchased a 3D LED Mag light yesterday and the switch was of this variety. This is the first LED Mag host I have purchased. I purchased it over an incandescent host because I wanted to play with the new switch design and also compare the new reflector profile properties with the old design. Justin Case does the tower of your switch assembly look a bit shorter/different i.e. of the LED variety? I am curious if all the new D Mags will be this design or is it the LED variety only. Also hard to tell because the incandescent Mags commonly available could be all old stock.

I bought a 4D Mag less than a month ago from Amazon and the switch was of the previous style. So I was a bit surprised to see a different D Mag switch housing from flashlightking. The old vs new towers look the same to me. I have two scrap towers (one old, one new) that have been cut off and they are the same size.

 

[Linger]

Fulgeo,
the new led reflector is amazing. It fits over some cr-123 lights (ultrafire MCU-C7) if you take their bezel off, the Mag reflector acts as the most amazing turbo head. I can throw the hotspot of an mc-e modded mcu-c7 with new m@g reflector as well as solarforce masterpiece pro1 turbo head. Its a fantastic bonus piece of gear.

*new switch seems stock in LED's only, with incan you takes your chances. I purchased 2 silver m@gs, one 2Dled one 3D incan and incan had old style.

 

[mrartillery]

That sucks, I wonder why they're changing them? Cheaper manufacturing? I've bought 2 more 4D's and a 2D in the past few months and they have both have the previous style switch, i dont think i'd like this new one to much.

 

[Fulgeo]

Fulgeo,
the new led reflector is amazing. It fits over some cr-123 lights (ultrafire MCU-C7) if you take their bezel off, the Mag reflector acts as the most amazing turbo head. I can throw the hotspot of an mc-e modded mcu-c7 with new m@g reflector as well as solarforce masterpiece pro1 turbo head. Its a fantastic bonus piece of gear.

*new switch seems stock in LED's only, with incan you takes your chances. I purchased 2 silver m@gs, one 2Dled one 3D incan and incan had old style.

Can not wait to play with it. It is a bit longer over all than the incandesent reflector.

 

[Fulgeo]

I bought a 4D Mag less than a month ago from Amazon and the switch was of the previous style. So I was a bit surprised to see a different D Mag switch housing from flashlightking. The old vs new towers look the same to me. I have two scrap towers (one old, one new) that have been cut off and they are the same size.

I just compared the Mag LED tower to one of my Mag incandescent towers. The tower itself is almost 3/8ths of an inch longer on the incandescent Mag. Not a big deal when you cut them down but I also noticed that the shorter Mag LED tower is needed with the Mag LED reflector which is longer than the incandescent reflector is over all length.

Mag LED => shorter switch assembly but longer reflector.

Mag incandescent => longer switch assembly but shorter reflector.

The exterior dimensions of the two lights seem the same but I noticed than if you screw the flashlight head all the way down until it runs out of threading the incandescent Mag is flush with the inner flat bottom of the flashlight head. The Mag LED head is about 1/16 of an inch higher. Not sure if this varies alot from Mag to Mag but wanted to mention it.

 

[Aircraft800]

The tower on the LED is not only shorter, but it has a larger diameter. I really like it for LED mods because the "+" terminal comes out easily, and is easy to isolate it from the switch for momentary switch mods for taskLED drivers. I can see where flat top cells could be a problem, but with the extra parts you removed from the tower, you have a new nice spring and cap you could use to make your battery contact.

The innards of the switch are the same. (sorry, I got this picture AFTER the momentary switch mod, so the ribs are missing on the plunger)

The new switches "+" contact come out so easily!

 

[elumen8]

JamisonM did a great comparison of the old incan and new LED switches.

Here's the thread http://www.candlepowerforums.com/vb/showthread.php?t=250681

JB

 

[Justin Case]

In comparing JamisonM's photos with mine above, it seems that the lower "barrel" section of the Rebel switch is the same as the lower "barrel" section of the new incan switch. However, the tower sections are different. I hope that the shorter height of the barrel section doesn't screw up the focus for the various super bulbs used in the JimmyM regulator/Kiu socket switch mods.

I also want to clarify that I ordered a replacement D Mag incandescent switch from flashlightking. What I've been discussing is the apparent change in D Mag incandescent switches, not the difference between the Mag LED and Mag incan switches.

 

[Billy Ram]

I like the new style switch.

Here's what you do for IMR batterys.
Billy

 

[Justin Case]

I clipped off a few turns from the unneeded incandescent bulb spring and soldered the spring stub to the Batt+ contact. Works fine, very easy to do.

 

[PapaLumen]

I just bought a 4D mag for a project, it too has this new style switch.
I noticed if you slide out the + contact you can flip it over and it looks like this:

A help for those with flat top cells...

I havent found a pic of this new switch modded for momentary etc, interested how people are connecting the + wire to this contact....

 

[Aircraft800]

Momentary Mod:

Remove the "+" battery terminal, new style Mag switch.

Chuck up this switch part in your lathe, or in my case my drill :mecry:

Remove the lobes so the switch doesn't lock.

Switch breakdown.

Now a momentary to ground switch for taskLED drivers.

"+" battery terminal with lead.

A little liquid electrical tape to further isolate the ground from the nearby positive battery contact plate. On the newer
taskLED drivers, you will not run this lead to ground lug like I did, you will run it directly to the driver.

Running the new always hot "+" lead around the switch.

 

[wquiles]

Nice pictures Matt

 

[PapaLumen]

Thanks Aircraft800, thats just what i was looking for :thumbsup:
Bit simpler that what i had in mind too, perfect.

 

[Techjunkie]

I'm guessing that because it hasn't been mentioned here already, that no one who has received the new Mag D incan switch had a problem with the ground screw like I did. That's a relief.

The new 2D incan I picked up at Home Depot last month (came in blister packaging with two Duracell Ds included) had a ground/grub screw that I couldn't tell whether it was defective or if mag had changed from a 2mm hex pattern to a torx or torx security bit pattern. I had to replace the screw in my new switch with one I had left over from an old damaged switch. I guess the screw in mine was just defective.

 

[mrartillery]

You're not alone, lol.