Battery rattle in single cell twist lights can be avoided with a foam doughnut. Another benefit is that the foam doughnut adds some protection against unintentional actuation of the light since the final twist takes a little more effort. Some lights come with doughnuts, and many find that corn pads can be adapted. I make my own foam doughnuts using a variety of custom tubular cutters, but few want to bother with this approach.
An easy way to make inexpensive doughnuts for the KD SX0H AAA Buckle and similar lights is to start with a sheet of 2mm thick hobby foam. I bought a bunch of 9" X 9" sheets in various colors at WalMart. The regular price was about 25 cents, but they were on clearance for only 10 cents per sheet. One sheet can make about a hundred foam doughnuts (much cheaper than corn pads). Place the foam on the back of an old magazine over a hard surface and use the tailcap itself as a tubular cutter. Stabilize the foam sheet and press firmly, rock and rotate the tailcap without lifting until a circle is cut from the foam. It will be the perfect size to fit the inside of the tailcap. Next, use a 1/4" (or 5/16") paper punch to make a hole centered on the disc. Some will prefer to reverse the sequence and use the paper punch first and cut the disc second. While you're at it, make half a dozen.:thumbsup:
An easy way to make inexpensive doughnuts for the KD SX0H AAA Buckle and similar lights is to start with a sheet of 2mm thick hobby foam. I bought a bunch of 9" X 9" sheets in various colors at WalMart. The regular price was about 25 cents, but they were on clearance for only 10 cents per sheet. One sheet can make about a hundred foam doughnuts (much cheaper than corn pads). Place the foam on the back of an old magazine over a hard surface and use the tailcap itself as a tubular cutter. Stabilize the foam sheet and press firmly, rock and rotate the tailcap without lifting until a circle is cut from the foam. It will be the perfect size to fit the inside of the tailcap. Next, use a 1/4" (or 5/16") paper punch to make a hole centered on the disc. Some will prefer to reverse the sequence and use the paper punch first and cut the disc second. While you're at it, make half a dozen.:thumbsup:
