Maglite Mod - possible on the cheap? < $100

[naiter]

:bow:CPF flashlight mod experts, I need your help!

Sometimes I feel like I’m the only CPF member who doesn’t have a 1000+lm Maglite mod.

I have had the thoughts. Dreamed of going extreme 'n overboard and make a super crazy custom massively bright modified Maglite. It’d feel good to accomplish a project like that.
But let’s be real. For me right now “Keep it simple stupid”

I have two ancient mags I don t use (2D and 3D) and one newer 3D LED mag, that the kids use on camping trips. Any could be the host body but I prefer to not break the LED one. The other two haven’t had batteries in em for years. I have thermal paste and basic tools. That’s about it… but I’m handy like MacGyver with electronics.

When I first started to look at battery holders and heats sinks and LEDs and drivers, I quickly realized that this wasn’t going to be cheap. SO why don’t I just buy a real light that looks good and is built better? Cuz I hear of all these “drop ins” that people make sound so easy…

Can I mod one on the cheap. Under $100 said and done. for 4 digit lumen. ??

I’d prefer to use Eneloops, but I have many of the same RCR123s too.

Can you guys please point me at some links for a simple NOOB Maglite build? It seems to be more work, time wise, collecting the info and parts, then assembling them. Maybe I will do a 2D and 3D build at same time since im going through the trouble. With two different “drop ins”.

Looking for pointers like: “all you need is this drop in (link), with this battery holder (link), mod the switch and you’ve got a 1500lm light!”

I know I’m asking something I could research but it’s like a needle in a hay stack at CPF! I don’t see the ‘simple’ mod going on. I know you guys know where it is.

Plus even though I am trying to be cheap , this is the first time I actually have the money to buy the parts, hence the cheapness vs. just dreaming…

Thanks in advance!!

Edit:
I'm getting DW's Triple Cree XM-L U2 Dropins for D size Mag-Lites
I guess CHEAP is not going to happen... but good value IMO, hoping for 2500+ LED lm in the end.

Edit 11/27/12
DW's dropin is in the mail!!
Metal reflector on its way from Kaidomain, so that'll take forever...
2 Lenses + Pelcian ROP bulbs on the way from lighthound.
battery rigs all to pricey right now, so i'm ghetto rigging 4 AAs sidebyside with no boring.
maybe later i'll do a bored chrome mag and proper holder but its too pricey right now...

 

[Cooper_GTI]

You don't necessarily say if you specifically want an LED light?

Check out ROP or 'roar of the pelican'. I think this gives close to 1000 lumens with the high bulb, driven properly. You'd get some change out of $100 and it's very easy to do!

 

[Thr3Evo]

A quick Google search: http://www.google.com/search?q=Maglite+drop+in&sitesearch=www.candlepowerforums.com

Or if u want, piece it together yourself. At dx a reflector(that fits the mag with no modification) with pill, xml, and amc7135 driver will run u about 25 bucks. If u pot the driver to the body of the mag and use good thermal compound under the led and don't leave the light on for long periods of time you won't need additional heat sinking. I have one like this and has been a great light for a long time, although I've shortened it(by human lathe method) for a more wow factor and also to run off a beefy 26650/32650 for more capacity and longer run times. You can leave yours long just use a dummy cell or provide appropriate voltage(one li-on's worth).

Or if u want a drop in all done with no hassle try a Malakoff for around 1000 lumen.

This is a bad a$$ lil setup also but requires 4 li-on's:

http://www.candlepowerforums.com/vb/showthread.php?t=314981
Triple Cree XM-L T6 Dropins for D size Mag-Lites

 

[tattoosteve99]

One word Jayrob 🙂

 

[Norm]

My preference would be for Mag 11.

With two Li-ion cells you should see around a 1000 lumens.

Norm

 

[naiter]

You don't necessarily say if you specifically want an LED light?

Check out ROP or 'roar of the pelican'. I think this gives close to 1000 lumens with the high bulb, driven properly. You'd get some change out of $100 and it's very easy to do!

Nice recommendation! I wasn't even thinking of a Xenon High Pressure bulb. All I’ve really seen on Xenon bulbs is the “wicked laser” torch that they only use to cook food or light campfire.:duh2:
Doubt I’ll actually use a single mode light that gets ridiculously hot, but It’d be cheaper, and a great toy. Maybe do a 3D LED build and a ROP build for the 2D. :thinking:

A quick Google search: http://www.google.com/search?q=Maglite+drop+in&sitesearch=www.candlepowerforums.com

Or if u want, piece it together yourself. At dx a reflector(that fits the mag with no modification) with pill, xml, and amc7135 driver will run u about 25 bucks. If u pot the driver to the body of the mag and use good thermal compound under the led and don't leave the light on for long periods of time you won't need additional heat sinking. I have one like this and has been a great light for a long time, although I've shortened it(by human lathe method) for a more wow factor and also to run off a beefy 26650/32650 for more capacity and longer run times. You can leave yours long just use a dummy cell or provide appropriate voltage(one li-on's worth).

Or if u want a drop in all done with no hassle try a Malakoff for around 1000 lumen.

This is a bad a$$ lil setup also but requires 4 li-on's:

http://www.candlepowerforums.com/vb/showthread.php?t=314981
Triple Cree XM-L T6 Dropins for D size Mag-Lites

Great Feedback, thank you. This second link is exactly what I was looking for!!! I knew it'd exist by now! I’ll probably end up sending more, but wouldn’t have to worry about the build quality!

All terralux ones I have found look like they are terrible quality for the higher price. maybe at DX price ranges...
And I was hoping to spend less than Malakoffs, with more output. All I saw was single XM-L for $70 without driver. there might be stuff I haven't found yet.

Time to try find the pieces separately to see if its even possible to beat Der Wichtel's badass pre-built drop in...

 

[naiter]

One word Jayrob 🙂

I was drooling looking at his custom lights all night last night...

My preference would be for Mag 11.

With two Li-ion cells you should see around a 1000 lumens.

Norm

Love that link! thanks Norm!

 

[naiter]

Pulled the trigger on DW's triple XM-L dropin.
http://www.candlepowerforums.com/vb...ple-Cree-XM-L-T6-Dropins-for-D-size-Mag-Lites

So excited!!
Now to figure out how to rig up the batteries...

Still want to buy FIVEMEGAs deep reflector for a ROP, but all good colors are gone.

 

[Thr3Evo]

Congrats, come back when it's all done and share.

As to power the beast, the seller recommends 4-5 li-on's. That's somewhere in the range of 15-20+ Volts. That might prove problematic in your setup of 2 and 3D lights.
My first instinct was 4x18650 in a U shape formation, something like this(yeah this is AA but I couldn't find 18650 one in a hurry) :

But this would require some boring out to fit the cells side by side and also making the ends of the holder + and -, rather than both at same end(this is a simple solution).
Well that's work.
Another solution is same setup with smaller cells but less runtime. This is something to think about.

If u don't want to do all that, you can use 3x (4xAA) round holders. Something like this:

This should give you about 18V and that's well within the required range.

Oh and one last but probably least favorable solution.... See if the seller is willing to make u a custom dropin with the multi man's mod so u can use it off one 32650. Decent run time and huge wow factor. I've got a self built setup like this and I highly recommend it.

 

[naiter]

Thanks for you input Th3Evo!
I think the battery config is going to be the toughest part of the build.

Here is what I am tossing around. ((first two would require me buying another mag...))

option 1:
-- 4D mag - 15x eneloops, which would still need 4x custom 4AA holders and one AA spacer to keep topped off voltage under 21v, running voltage be around 17.7v w/ 15 eneloops.

option 2:
-- 5D mag - 15x eneloop, which would be 5x 3AA purchasable holders, easier with same voltage results as above. (or use 5x 32650 for long run times?)

option 3: *toughest but best*
-- 3D mag - borded to made to fit 4x 18650s side by side +1 18650 rig to fit in tail cap. crazy tough battery rig to try and fit the 5th 18650 inside the tail cap. this would be tough to get bored and tough for the battery holder, but would have good run times to size ratio, and use convenient batteries. similar voltage results as the 15x eneloop.

check out post #10 here:
http://www.candlepowerforums.com/vb/showthread.php?281565-18650-Holders-for-D-Mag-Mods

option 4:
-- make a super stubby mod down cut mag with 14500 x4 , tough build, less output vs 5x 3.6v, but nice WOW factor cuz of size...

option 5: *easiest*
-- 2D mag with 5x 14500s in 2x 3AA holders + 1AA spacer... hmm might be easiest but bad run times. (this would also give me a not as bright light, if running 7.2v on 6x eneloops when in a tight spot...) and I only have one other light that uses 14500s


guess my "cheap" isn't happening... lol
Any thoughts?

 

[Thr3Evo]

All those enloops are going to be a chore to charge.

I like option 3 although I think u can get away cheap and easy with one of the 4x18650 holders and a bit of a bore work... Not really necessary for a full bore just some slots at 12 and 6 o'clock on the mag tube enough to fit the cells side by side. Try this option without the extra cell, I think it's ur best bet and u are going to be very pleased with the amount of light those xml's will provide. If at a later time u want to experiment u can change the setup.

I take it the option with a single 32650 is not really an option?

Also I remember seeing somewhere the possibility of custom battery packs. They come in this gel looking pouch and kinda mold to their surroundings making them easier to fit in tight spaces since no hard outer shell is required. Google it and see what comes up.