KL2 mod with pics

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Chop

Flashlight Enthusiast
Joined
Jul 22, 2003
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Louisiana
Hey guys,

I was recently asked to see what I could do with a KL2. Since I don't have a lathe yet, I was really limited in what I could do, but I did come up with something. For those that have a KL2, this might be a way to breathe new life into that KL2. If you can do a McLux build, you can do this. Below are pics of the modded KL2. On the inside are a Downboy biased at ~850mA with a TWAK 3W and a PR.

The first shot is for comparison purposes. It is a KL1 biased at ~700mA with a Q3J and an NX05 optic. Both beam shots were taken in a dark room about 30 feet from a white wall. Sorry, it's the best I could do.

First the KL1...
fa56f2a4.jpg


Next is the KL2 mod with the TWAK at 850mA with a Pelican M6 Reflector...
fa56f29e.jpg


This is what the beam shot above came out of...
fa56f29b.jpg


And the business end...
fa56f29a.jpg


fa56f298.jpg


The pics don't really show it, but there was a spacer used for the 19 leds that were in there. It turned out that this spacer was easy to adapt to the Pelican reflector.

Now the tail end...
fa56f294.jpg


While doing the mod, it turned out that desoldering the leads from the springs was all that was connected to the post that supports the springs. The post actually unscrews with what can and was used as a heat sink and nook for the Downboy circuit. All it took to get the whole head a part was a bit of heat and needle nose pliers.

I should mention that the support for the stock board containing the leds and resistors (I think) just got in the way. I cut this away using a rotozip bit on my Dremel tool.

The KL2 head turned out to be really mod friendly. It just so happens that the way the post fits into the head affords a direct path for heat to the head and the body. I ran it for an hour straight and it never got more than warm.

Of course, I don't have to say anything about the throw. It was typical 3W with a PR. It easily lit things up out to 100+ yards.
 
So, ya gonna do an L5 or L6 next /ubbthreads/images/graemlins/grin.gif It does appear that a bigger reflector can fit in there. Is there any more depth as well since a bigger reflector probably means a proportionately deeper one.

CM
 
CM,
There is more room. I have the bezel ring tightened all the way down holding the reflector in place. There is actually a bit of play room in back as well, in that the post can be loctited in a location something short of all the way in. What I'd like to do is to do away with the spacer all together. When I get the lathe, I'm gonna play with a mag reflector first and see where that leads.
 
Chop, what did you do with the original KL2 guts? I'm mighty interested if they're still somewhat intact. /ubbthreads/images/graemlins/smile.gif

Jon
 
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Cool mod Chop! Looks like plenty of room for a ring of 3 mm's around the reflector! /ubbthreads/images/graemlins/grin.gif
 
Don,
That's an idea, but beyond my capabilities at the moment. Maybe not. I'll have to look into that. I'm not really up to speed on switches though. Maybe if I can figure out how an A2 switch works, that would be the ticket.

Geez Don, now you've got me thinking. The KL2 above was for a customer, so now I'll have to get another KL2. It looks like this is going to be one I'll have to try and draw up. It's been a while since I've used CAD. I guess that's my next project.

Man, these mods can get out of hand.

If it was up to me, I would have gone with a 5W setup. The M3/KL2 combo makes for a pretty big light and should put out lots of light. I'm thinking something in the flavor of a DD, in Mr. Bulk fashion.
 

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