I present to you, a prototype 9AA>3D adapter. 6AA>2D coming.

mdocod

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I have a thread running on the interest of some battery carriers. That thread started as my intent to design a 3AA>1D carrier that could stack end to end, and followed my progress, which quickly transformed into a different strategy, as the necessary hardware for a good well built carrier just can't be set up in a 3AA>1D size without going over the 1D length. That thread has become long and difficult to work through (mostly my fault, as I tend to ramble way too much... here I'll prove it..)

I've decided to start a new thread to share some of what I am working on. Before I get started: [This Is Not A Sales Thread]...

I am merely wanting to take this opportunity to share with the CPF community my new battery carrier design. I will add updates in the next few weeks with information on when I intend to start a sales thread (I intend to build and sell these when I have a working method of building them efficiently figured out)

Also, in case anyone is interested in building their own carrier based on these designs, I am going to start a thread somewhere (either here or in the home-made/modified section) with complete instructions and details on building one yourself. I'll have that thread up and running probably somewhere in early 2008 hopefully. My feeling is that I wouldn't be doing this if it weren't for CPF. The design I have come up with belongs to CPF. The advantage of the design is that most home garages with a few tools can build this very decent quality adapter in an afternoon provided you gather the right fasteners, bits, plastic rod, and pieces parts. However, the cost of building one will probably not be much if any cheaper than ordering a completed one from me (as there are minimum order quantities for the plastics, and fasteners bought in small quantities at places like Ace cost a lot per piece).. But I think the option should be there to do so. All I ask is that no one begin production of this design with intent to sell.

For now, On to the pictures:
100_2645.jpg

100_2644.jpg

100_2643.jpg
 
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Ah, you have a design similar in concept to one I've been working on. Mine is the same basic structure as yours, but different materials and construction methods.

How do you feel about the cells springing out of the middle if the flashlight is dropped or something? A Mag barrel is a snug fit, but not all flashlights are like that.
 
inside of a flashlight barrel they aren't going anywhere. Unless it was a VERY loose barrel, even then, with the end caps tightened down decently they hold themselves in pretty well.
 
With a typical cylindrical flashlight, it's true the cells and holder will be a snug fit. But I also have a 4 cell lantern style light where there is a lot of empty space around the batteries and no tight flashlight tube surrounding them. In that case the cells might need a little extra restraint in the holder.
 
this my friend will be a sticky among stickies... absolutely brilliant!! i salute you!
 
With a typical cylindrical flashlight, it's true the cells and holder will be a snug fit. But I also have a 4 cell lantern style light where there is a lot of empty space around the batteries and no tight flashlight tube surrounding them. In that case the cells might need a little extra restraint in the holder.

i will save up some paper towel tubes for Mr happy :)
 
I really think for the first design to work you need the precision of a lathe. Also, if you are still concerned about the threads in the plastic stripping or wearing out over time, you could epoxy in some threaded inserts.
 
This design uses a #10-32 threaded nylon rod through the center, so far in my experimenting with this size rod, it has the strength to handle the design and could probably crush cells before you would strip the threads. However, because it is a readily available part at low cost replacement pieces could be made very easily and quickly if something were to happen.
 
I'd love to get one of these for my 2D Maglite. Then I could drive a Malkoff Device at 9V with some NiMh cells.
 
good news guys! I ordered enough fasteners and plastic to get going on this, It should all be here by the end of the week. I'll begin making these next monday. (I work all weekend at my other job)....

keep an eye out in BST! I should have these up for sale within 2-3 weeks now!
 
Hi mdocod
I was wondering if you had any afterthought brilliance to a D-cell 3AA mod.
something like those 3aaa holders but with only 1.2volt output.
i.e. 3AA's in parallel. Seems logical to me but then so does snow-camping...
The impossible just takes a bit longer!
Dcell3AAmod.jpg


hopkins
 
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My lame idea was to let the Mag tailcap spring hold the '3AA mods'
together. Round thin plates at the + & - ends to connect the 3AA's
into one D-cell sized cylinder of 1.2volt. - and some sort of plastic
fins or struts that would keep the AA's arranged... so the length
would only be increased by the thickness of the 4 'plates' in
a 2D cell Mag application.
What do you think? DOA idea?
 
hehe...

I'll happily take orders for parallel wired packs if you want them, it's about the same amount of work either way for me to make one that wires in series or parallel. So if you are interested in a parallel pack of 6AA (sets of 3 in parallel, sets of 2 in series, for ~2.4V operation with the capacity of 3 cells combined) or 9AA (sets of 3 in parallel, 3 in series, ~3.6V operation with the capacity of the 3 cells combined), just let me know when I get the sales thread up and running. I'll have options like "parallel pack" "series pack" "charging leads with alligator clips" ...

This is not an unusual idea at all.. Since I started talking about making these carriers I have had at least a half dozen requests to make parallel packs available. Which I will.
 
used google sketchup to draw this. something like this might work
I think...or not. Isn't it fun to design stuff to mod lights?
Probably needs a sleave to hold em all or more plastic etc..
3AADcellmod.jpg
 
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