DaFABRICATA
Flashlight Enthusiast
It needs to be refined and waterproofed(the stock rubber button cover snaps over the protruding nipple.....ummm can I say that...anyway, that would seem to help to waterproof the tailcap.
PICS ARE NOT IN ORDER
Tools and parts needed:
Surefire E-series LOTC, Very small drill bit/dremel tool, solder/soldering iron, a few small washers, a small diameter spring, a small plastic or non conductive sleeve, pressure pad switch, Patiance
1. Take apart LOTC, use needle nose pliers and remove spring, next remove allen head screw, unscrew black plastic retaining disc, pull insides out completely. You should have an empty shell now.
2. Drill a hole in the Aluminum disc with the o-ring the same diameter as the wire going through it. (see pics) Next drill 2 small holes in the black plastic disc. slide 2 small cut lengths of solder and put through the holes in the black plastic disc. (see pics)Now solder each side so it mushrooms out and provides contact on either side of the black plastic disc. File them down so they are just a little higher that the disc.
NOTE: when reinstalling aluminum disc turn over first! BACKWARDS from original, ALSO, shrink wrap the contact spring leaving only enough to make contact to the bottom of the battery. The wire going into the tailcap needs to stay into position... some how...(still workin on that)
3. Insert wire through hole in the aluminum disc. Make one wire a decent length & remove most of the jacket(see pics)
Next run the longer bare wire over the side and around the disc,(see pics)
Next put the short wire through the washer and onto the longer wire.
Next screw the black plastic disc down onto the washer. This will hold the longer wire down and provide contact to complete the circuit. (See pics)
Next. install plastic sleeve over short wire. Now solder the short spring onto the short wire (spring needs to be cut shorter than in pics).Now put in final washer. NOTE:this final washer must make contact with the battery tube.
DONE.
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