EssLight
Newly Enlightened
Not a complete meltdown, but a significant warping of a plastic reflector.
What I was trying to do was make a cheap substitute for a Brinkmann Maxfire XL. I bought one of those last summer, I like it, I was bummed when Target put them on closeout and I couldn't find any.
The idea was to put 2xCR123 batteries with a Mag 4 cell Krypton bulb. I have done that successfully in an old Black and Decker Snakelight.
The flashlight that I chose to modify was an Eveready Industrial 2AA Flashlight ($4 at Home Depot).
It is a plastic flashlight which uses a PR bulb. The body is made larger than the AA cells it holds, there are plastic ribs on the inside that you can shave off to make it large enough to fit CR123 cells. I tried modding one of these flashlights last summer, to hold 3xCR123 and a 6 cell bulb. That one melted quick. I was hoping that the plastics would be able to handle the reduced heat of a 4 cell bulb.
I put the light together, and at first, it seemed OK. Running it for short bursts, I couldn't feel any significant heat around the head. I decided, if I really want to be able to use this light, I want it to run for 10 minutes continuous without melting.
So, I ran a test. I put a pair of fresh cells in the light, switched it on, and most of the time had it tailstanding on a table. I kept frequently checking the integrity of the lens. When I built the 3xCR123 light, the lens was the first thing to go. I was very satisfied when the new light went a full 10 minutes, and the lens never got soft or distorted.
Then I opened the light for inspection. The batteries were fine, slightly warm, but not hot. The bulb holder seemed OK. Then I looked at the reflector and saw this:
The facets are supposed to run all the way to the edge of the bulb. The areas that are smooth are actually parts that started to melt and warp. I then also discovered that the bulb holder is now crooked:
The spring pressure applied to the batteries had pushed the bulb holder up and off center. (As a side note, all these images were taken using a flatbed scanner. In the above picture, the object on the left is a gray mechanical pencil with a purple pocket clip which I put on the scanner to keep the bezel from rolling off.)
I did find out when I took the bulb out that there was a bit of warping that happened in the center of the lens. I couldn't see it with the bulb in.
Scratch another $4 light. At least it was cheap.
I was able to put the 2 cell bulb back in the light, pair it with a couple AA cells, and it still works. But with the warped reflector, there is a donut hole in the beam at any distance beyond 2 feet.
The picture of the light in the packaging earlier in this thread was actually taken after the melting instance. I try to keep original packaging intact in case I ever need to return something. Do you think Home Depot would take this back? It looks normal from the outside.:naughty:
Just for the record, no, I am not going to try to return it.
Now I am trying to think of plan B for a Brinkmann Maxfire XL substitute.
EssLight
What I was trying to do was make a cheap substitute for a Brinkmann Maxfire XL. I bought one of those last summer, I like it, I was bummed when Target put them on closeout and I couldn't find any.
The idea was to put 2xCR123 batteries with a Mag 4 cell Krypton bulb. I have done that successfully in an old Black and Decker Snakelight.
The flashlight that I chose to modify was an Eveready Industrial 2AA Flashlight ($4 at Home Depot).
It is a plastic flashlight which uses a PR bulb. The body is made larger than the AA cells it holds, there are plastic ribs on the inside that you can shave off to make it large enough to fit CR123 cells. I tried modding one of these flashlights last summer, to hold 3xCR123 and a 6 cell bulb. That one melted quick. I was hoping that the plastics would be able to handle the reduced heat of a 4 cell bulb.
I put the light together, and at first, it seemed OK. Running it for short bursts, I couldn't feel any significant heat around the head. I decided, if I really want to be able to use this light, I want it to run for 10 minutes continuous without melting.
So, I ran a test. I put a pair of fresh cells in the light, switched it on, and most of the time had it tailstanding on a table. I kept frequently checking the integrity of the lens. When I built the 3xCR123 light, the lens was the first thing to go. I was very satisfied when the new light went a full 10 minutes, and the lens never got soft or distorted.
Then I opened the light for inspection. The batteries were fine, slightly warm, but not hot. The bulb holder seemed OK. Then I looked at the reflector and saw this:
The facets are supposed to run all the way to the edge of the bulb. The areas that are smooth are actually parts that started to melt and warp. I then also discovered that the bulb holder is now crooked:
The spring pressure applied to the batteries had pushed the bulb holder up and off center. (As a side note, all these images were taken using a flatbed scanner. In the above picture, the object on the left is a gray mechanical pencil with a purple pocket clip which I put on the scanner to keep the bezel from rolling off.)
I did find out when I took the bulb out that there was a bit of warping that happened in the center of the lens. I couldn't see it with the bulb in.
Scratch another $4 light. At least it was cheap.
I was able to put the 2 cell bulb back in the light, pair it with a couple AA cells, and it still works. But with the warped reflector, there is a donut hole in the beam at any distance beyond 2 feet.
The picture of the light in the packaging earlier in this thread was actually taken after the melting instance. I try to keep original packaging intact in case I ever need to return something. Do you think Home Depot would take this back? It looks normal from the outside.:naughty:
Just for the record, no, I am not going to try to return it.
Now I am trying to think of plan B for a Brinkmann Maxfire XL substitute.
EssLight
Last edited:
