High-Temperature Lamp Holder for D-Cell Maglites

[Snoopy]

Various attempts have been made recently to install single-ended halogen bulbs into Maglite D-cell bodies. The operation temperatures of these bulbs definitely prohibit the use of any plastic parts in or near the pin socket. The lamp holder introduced here solely uses metal and ceramic components to assemble the mechanical link between bulb and body tube.

The device (Figure 1) consists of a base plate, two threaded bolts, a GY6.35 halogen socket and three mounting screws. The bolt length allows for a coarse positioning of the lamp filament for different bulb sizes and reflector geometries. I use the snap ring near the front end of the body tube to mount the holder, Figure 2 (sorry, bad picture). The wires are passed through a hole in the base plate.

Figure 1: High-Temperature Lamp Holder

Figure 2: Lamp Holder installed

The base plate is the only part that needs to be made on a lathe. There may be more simple solutions, but the precision achieved this way ensures a good centering of the bulb within the lamp body.

I've tested the holder with bulbs up to 100W for 5+ minutes and not noticed any damage so far. As soon as I have the time I'll post some temperature measurement results.

Regards,
Snoopy

 

[KevinL]

Re: High-Temperature Lamp Holder for D-Cell Maglit

/ubbthreads/images/graemlins/ooo.gif do I smell a product that could revolutionize the way we work with hotwires forevermore? No more melted bipin slugs?

All I can say is WOW, GREAT JOB!!! How much are these going to run and are you planning to offer them on CPF?

 

[Ginseng]

Re: High-Temperature Lamp Holder for D-Cell Maglit

Nice entry, Snoopy,

Please show some pictures of how it is held in place inside the flashlight body and integrated with the switch (either original or replacement).

I assume the two pedestal "legs" can accommodate the typcially smaller G4 ceramic sockets for use with Welch Allyn bulbs?

Oh, and the ultimate tribute... /ubbthreads/images/graemlins/paypal.gif

Very nicely done.

Wilkey

 

[paulr]

Re: High-Temperature Lamp Holder for D-Cell Maglit

Wow, this is awesome, it would be great to have a G4 version and to get a production run done of the base plates (emachineshop or whatever). It could solve the whole MC slug issue once and for all, and of course opens the whole range of G6.35 lamps to day-to-day modding where they were once considered extreme. /ubbthreads/images/graemlins/bowdown.gif /ubbthreads/images/graemlins/bowdown.gif /ubbthreads/images/graemlins/bowdown.gif /ubbthreads/images/graemlins/thumbsup.gif /ubbthreads/images/graemlins/thumbsup.gif

 

[nexro]

Re: High-Temperature Lamp Holder for D-Cell Maglit

Nicely done.
Would definately like to see more pics of how you did this /ubbthreads/images/graemlins/smile.gif

 

[AW]

Re: High-Temperature Lamp Holder for D-Cell Maglit

Deleted

 

[Kiu]

Re: High-Temperature Lamp Holder for D-Cell Maglit

/ubbthreads/images/graemlins/goodjob.gif, Snoopy. You should have a lot of fun now. /ubbthreads/images/graemlins/smile.gif
Not sure about your bulb socket. Mine is rated at 120W
. But I guess they are similar in functions, both can withstand high temperature. Mine can fit the WA's bulbs, G6.35 and G4 bulbs.

Some similar mod here: Web1 web2
Looks quite similar /ubbthreads/images/graemlins/grin.gif

BTW, what kind of 100W bulb are you using in the pics?

 

[AW]

Re: High-Temperature Lamp Holder for D-Cell Maglit

Very nice job here.

Kiu,

Very nice... /ubbthreads/images/graemlins/naughty.gif /ubbthreads/images/graemlins/buttrock.gif

 

[Snoopy]

Re: High-Temperature Lamp Holder for D-Cell Maglit

First of all I'd like to thank everybody for the overwhelming response! Now let me try to answer some of your questions.

[ QUOTE ]
How much are these going to run and are you planning to offer them on CPF?

[/ QUOTE ]
I'll check how much machining the base plate would cost (this will probably be the most expensive component and determine the cost for the complete item) and start a 'feeler' a.s.a.p.

[ QUOTE ]
Please show some pictures of how it is held in place inside the flashlight body and integrated with the switch (either original or replacement).

[/ QUOTE ]
The lamp holder is dropped into the body tube from the tail cap side. The base plate lies behind the snap ring (i.e. on the switch side) and is held in place by the three screw heads which clamp the snap ring from the other side. Unfortunately, I don't have a better picture than the one posted above, but maybe this drawing will do:

Regarding the switch, I'll write another post on this tomorrow that describes how the original switch is modified to work with high current halogen bulbs. So please stay tuned.

[ QUOTE ]
... it would be great to have a G4 version ...

[/ QUOTE ]
The pin contacts are wide enough to accommodate any bulb from G4 to G6.35. If you would like to use your own socket, for mine the distance between the two mounting holes is 12mm (~1/2 inch).

[ QUOTE ]
... what kind of 100W bulb are you using in the pics?

[/ QUOTE ]
The bulb is an Osram 64625 HLX (3600lm).

[ QUOTE ]
Would definately like to see more pics of how you did this

[/ QUOTE ]
Coming up soon ...

Best regards,
Snoopy

 

[greg_in_canada]

Re: High-Temperature Lamp Holder for D-Cell Maglit

Would an appropriate size fender washer work for
the base plate? It would already have the center hole
for the wires but you would need to drill the holes
for the posts and drill and tap* holes for the screws
that hold it in the light.

* I think you could get 3 threads of #4-40 in a typical
fender washer (though I don't have one handy to measure).

Greg

 

[Snoopy]

Re: High-Temperature Lamp Holder for D-Cell Maglit

Ginseng: Please find some more information on the connection of the lamp holder to the switch assembly here.

Regards,
Snoopy

 

[Snoopy]

Re: High-Temperature Lamp Holder for D-Cell Maglit

Greg: That's certainly a very good idea for a low-cost alternative. However, for a fender washer to properly fit into the body tube and securely be positioned behind the snap ring it must have an outer diameter between 32mm (1.26") and 34mm (1.33"). The standard sizes available here in Germany are either 30mm or 40mm. But the re may be something more suitable in Canada or the US.

Regards,
Snoopy

 

[js]

Re: High-Temperature Lamp Holder for D-Cell Maglit

Snoopy,

Very impressive stuff! Quite the way to enter the CPF world! I'm excited to see another hot-wire guy active on the mod forum. We're a small contingent here compared to the LED folks. And you've already done some top-notch stuff.

Thanks so much for bringing this to CPF. I'm interested in getting one (or more) of these holders when (and if) you offer them.

/ubbthreads/images/graemlins/bowdown.gif /ubbthreads/images/graemlins/bowdown.gif /ubbthreads/images/graemlins/bowdown.gif

I salute you.

 

[greg_in_canada]

Re: High-Temperature Lamp Holder for D-Cell Maglit

I'll take a look the next time I get to a
hardware store.

Cheers - Greg

 

[mvnsnd]

Re: High-Temperature Lamp Holder for D-Cell Maglit

A quick search through Mcmaster-Carr reveals these candidates:

91950A035: 1.313 OD, .656 ID, .093 thk Stainless steel, $6.07per 10 pcs

and

98019A514 1.312 OD, .656 ID, .074 thk Stainless steel, $9.16per 20 pcs

--
Jeff

 

[Snoopy]

Re: High-Temperature Lamp Holder for D-Cell Maglit

Unfortunately, the ID is quite large (about the OD of the ceramic socket). Using these would require different bolts to attach the socket.

 

[js]

Re: High-Temperature Lamp Holder for D-Cell Maglit

Bump. This is good stuff and should have more exposure (and praise).

 

[mike2004]

Re: High-Temperature Lamp Holder for D-Cell Maglit

i second that

 

[baylisstic]

Re: High-Temperature Lamp Holder for D-Cell Maglit

bump