As other authors have noted, the switch for the Zebralight headlamps is prone to accidental activation. Sure, I try to remember to loosen the tailcap, but most of the time I don't.
So, I needed to find some way to protect the switch. What I did was start with DealExtreme SKU 5714, a GITD silicone tailcap. I cut off the flat button part, leaving a shallow tube with a flange on it. I then glued that flange to the flat area surrounding the button on my H501:
Sorry, I don't have the right to post images, Here is a link to the image
I used 3M UltraFlex adhesive to attach the modified cap to the light.
What worked:
The switch is well protected. I have not had any trouble with accidental activation, but can still work the switch, even with gloves.
Some people had problems, or at least concerns, with water getting into the switch. The groove between the light and the switch is completely covered by the DX tailcap, likely reducing the likelihood of water getting into the light.
There is a lingering glow from the GITD material, but it doesn't last long. If you drop the light, look for it quickly.
What didn't work so well:
The modified tailcap comes just to the edge of the light. On my first attempt, I didn't align the tailcap perfectly, and it hung off the side a little. This overlap eventually got caught enough to pull off the tailcap.
Gluing things made of silicone isn't easy. The Ultraflex does a decent job, but it's not great. I drilled small holes around the flange in an attempt to give the glue a better mechanical connection. (The small blobs of glue in the groove between flange and tube are the top of these holes.)
Possible refinements:
Rather than using the DX tailcap, an O-ring might work better. Ideally, it would fit into the groove between the switch cover and body of the light.
If there is a good glue to attach silicone parts, I haven't found it yet. The Ultraflex is okay, doesn't form a good bond with the DX tailcap.
Ted
So, I needed to find some way to protect the switch. What I did was start with DealExtreme SKU 5714, a GITD silicone tailcap. I cut off the flat button part, leaving a shallow tube with a flange on it. I then glued that flange to the flat area surrounding the button on my H501:
Sorry, I don't have the right to post images, Here is a link to the image
I used 3M UltraFlex adhesive to attach the modified cap to the light.
What worked:
The switch is well protected. I have not had any trouble with accidental activation, but can still work the switch, even with gloves.
Some people had problems, or at least concerns, with water getting into the switch. The groove between the light and the switch is completely covered by the DX tailcap, likely reducing the likelihood of water getting into the light.
There is a lingering glow from the GITD material, but it doesn't last long. If you drop the light, look for it quickly.
What didn't work so well:
The modified tailcap comes just to the edge of the light. On my first attempt, I didn't align the tailcap perfectly, and it hung off the side a little. This overlap eventually got caught enough to pull off the tailcap.
Gluing things made of silicone isn't easy. The Ultraflex does a decent job, but it's not great. I drilled small holes around the flange in an attempt to give the glue a better mechanical connection. (The small blobs of glue in the groove between flange and tube are the top of these holes.)
Possible refinements:
Rather than using the DX tailcap, an O-ring might work better. Ideally, it would fit into the groove between the switch cover and body of the light.
If there is a good glue to attach silicone parts, I haven't found it yet. The Ultraflex is okay, doesn't form a good bond with the DX tailcap.
Ted
