Help! I have a problem

[Timothybil]

I went to grab the EA4W that I keep beside my bed today and it wouldn't turn on at all. Upon inspection, I found that it was my son's EA4 instead. When I tried to open it to check the batteries, I could not budge the endcap. Neither could my much stronger son later when I asked him to. I am suspecting totally discharged leaking cells (alkalines) if I ever get it open. Any ideas on how to do that without marking up the exterior with wrench marks? I am thinking two strap wrenches, which I don't own now, but suspect I may shortly. Unless I take the light to my local Wally World and kinda borrow a couple from the tool display for a minute or two. Any other ideas? Should I soak the end in hot water for a while first?

 

[Timothybil]

Where did it move to?

 

[Rosoku Chikara]

I think I have read something about applying painter's tape (masking tape?) first, and then applying several layers (or possibly, many many layers?) of Duct Tape to protect your flashlight from robust hand tools such as pliers, or vice grips.

Once you have done that, you should probably be able to "safely" use vice grips, or some other good hand tool to achieve a very solid grip on your flashlight. (Be careful not to apply so much pressure that you accidentally "collapse" or otherwise "dent" the flashlight barrel itself with the vice grips, or other similar pliers.)

Assuming that you have done everything "correctly," then the "painter's tape" (masking tape?) should make it easy for you to remove the Duct Tape when you are finished.

 

[bedazzLED]

Here is a link on opening stuck flashlights I found on the forum a while ago.
http://www.candlepowerforums.com/vb...lued-threads-HOWTO-without-tools-no-damage!!!

 

[HotWire]

I would use penetrating oil on any part that could be screwed off (like the cap or head). Let that sit overnight, tap the light with a piece of wood and apply more penetrating oil. Then use the methods described above. Leaking alkaline batteries is a real problem. Try to avoid them. Use lithium primary or nimh batteries instead....

 

[Timothybil]

Well, my son got the cap off. Combination of leaving it in the car to get hot for a day or two and muscles I guess. I was right, two of the Maxells leaked (one for sure, maybe on the other). The leakage appears to be at the cap end. I soaked end upright in some warm baking soda and water, and used qtips cut at an angle to clean out the body threads and regular qtips to clean the inside. Let it dry for a couple of hours and put in new batteries but no go. Will wait another day and try again while I try and find my Dremel tool. The endcap contacts look okay, but a little sanding never hurt anyone. Will also find my multimeter and check continuity on those contacts.

Wasn't able to find any kind of battery warranty on the Maxell site. Have any of you had problems with Maxell alkalines and/or dealings with Maxell customer service?

 

[Norm]

How to Clean Battery Leaks/Spills.

Norm

 

[Timothybil]

I couldn't find anything about battery warranties on the Maxell site, so I emailed their customer service last night. I got a nice letter back from them asking me to send them the failed batteries along with appropriate documentation. Will keep all informed as we go along.

 

[Yorgi]

Best of luck with your cleanup. I would definitely try using a multimeter to check the tailcap.

This is another good reason to switch to Eneloops, no more exploding batteries. I only put Alkalines in devices that I will be giving away.