Intermittant L4, what to do?

[Pydpiper]

This is my second L4 to go intermittent, needs a good smack off something solid to turn on. I love the L4, it has been good to me over the years and I don't know what to do.
I am hesitant about sending it in for warranty, customs hammers me about $70 to come across due to Surefires need to use UPS.
So I would like to fix it myself, how do I take this thing apart?
Or, who makes them brighter? I would be happy with a brighter light only if it can provide the flood the L4 is know for.

Do it yourself take apart? How is it done? I have every tool from dentist picks to sledge hammers.

 

[Size15's]

If you've replaced the SF123A's with fresh ones then perhaps you're not screwing the KL4 bezel down tight enough? It has to be pretty tight. Sometimes the PocketClip can be protruding a fraction too much preventing the bezel to be tightened sufficiently. Could this be the cause?

 

[Pydpiper]

I wish it were that simple.
I swap the head back and fourth between a single cell body and the original that came with the Lumamax and back again using the KL1 with both too.
In this heads defence I have had it for a long time, it is "on" close to 3 hours a day and has been abused beyond what an average guy can do to a light.
I can feel the black insert inside it move when it is not attached to a battery tube(heat issue?), something is loose and I have no doubt it is in that KL4 somewhere. If there is a home brew way of taking it apart I am confident I can find the contacts that are skipping, I just don't want to apply brute force to the internals after years of applying brute force to the outside. It will be a simple fix if I can get it apart.
OR.. Have it upgraded, I made sure Surefire kept the same beautiful white tint I was afraid of losing the first time I sent it in for this same reason, they did good by me, it was the border that put the screws to the shipping bill.

 

[Size15's]

That is a bit of a dilemma...

Perhaps this is an opportunity to try something new?

 

[greenLED]

...
I can feel the black insert inside it move when it is not attached to a battery tube(heat issue?), something is loose and I have no doubt it is in that KL4 somewhere....

That sounds like a warranty issue, which is not something you wanted to hear, I'm sure.

There's countless threads on how to take the KL4 apart. DeFabricata is been on a KL4 modding spree recently; might as him.

 

[Pydpiper]

Thanks Al, I did, I got a shiny new Olight M20 in the mail today. It more than filled the shoes of my L4.
I love this light though, the L4 I mean. If I am going to retire it to my flashlight shelf I would sleep better knowing it was retired in working condition.

 

[asdalton]

Perhaps this is an opportunity to try something new?

The Inova T1-MP has a similar beam pattern to the L4, but with a lower price and much longer runtime.

 

[Pydpiper]

That sounds like a warranty issue, which is not something you wanted to hear, I'm sure.

There's countless threads on how to take the KL4 apart. DeFabricata is been on a KL4 modding spree recently; might as him.

Thanks Green, any chance of getting a link to just one thread on taking the L4 apart? Seems to be 1001 ways a guy can word that in a search, none are getting me any results.

 

[Size15's]

Well then you appear to have an opportunity to have your L4 sent away for repair

 

[greenLED]

Thanks Green, any chance of getting a link to just one thread on taking the L4 apart? Seems to be 1001 ways a guy can word that in a search, none are getting me any results.

Sure, Pyd. Here you go; kinda old, but should work:
Link 1
Link 2

It kinda opens the way a KL1 does, so searching for threads started by grnamin will give you more hints (and pics, IIRC).

Good luck!

...and it seems like you found your old thread from a couple of years back. Coincidentally, Greg posted a tutorial there as well. (Chop faded away after Katrina, BTW.)