HELP NEEDED! MagLite Mod...

[Alexcamp]

Hi, I have done some MagLite mod in the past with the 3-D cell model. The only thing i'd like to improve was the way my led module was connected to the power source. I couldn't find fittings that would drop in the existing bulb socket of the maglite so I had to dremel into the socket and solder the two wires directly on the socket parts. That meant disassembling the whole flashlight and also the mod was "permanent". No way to get back to the original configuration (who wants to anyway).

I am considering putting some of my led modules into production again with some up-to-date Nichias DS, but this time in a "Drop-in" configuration so that a user could interchange led modules or simply put the old incandescent bulb back in.

Here's where I need HELP: I need to find a fitting that would fit and lock inside the bulb socket of all those C or D cell maglites. The fitting needs to be long enough for easy modding.
Does anyone know where I can get this ???

Also, does anyone know of a source where I can get 5mm Nichias DS Leds ?

Any help is greatly appreciated. Here's a picture of the maglites I modded back in 2004 :

Thanks in advance!

 

[Mr Happy]

One option of course is to sacrifice an existing PR bulb. Just buy a few really cheap vacuum filled bulbs, carefully break and remove the glass envelope and then solder in your connecting wires.

You have two options for making the connections. One option is to remove only the top half of the glass envelope and use fine emery cloth to smooth it down to the metal base. This leaves the filament support wires in place to solder new connections to (of course you have to be careful not to destroy those wires when sanding down the glass to a smooth surface).

The other option is to remove the glass envelope and cement entirely, and then solder inside the metal base can. This could be very fiddly, but it is achievable. Note the existing solder connections on base and side where the bulb was originally connected. You can unsolder those and put in your own wires.

When you are done you can use hot glue or epoxy to create a strong mechanical assembly.

 

[Probedude]

Does it have to fit and lock? Like Mr. Happy said you can cannibalize PR flange bulbs or machine a shell to fit like on and then run your wires off that.