<BLOCKQUOTE><font size="1" face="Verdana, Arial">quote:</font><HR>Originally posted by KenB:
Well darn it, I just a few days ago ordered the Mini Trek but asked them to send me the PLW-3 insert instead of the 2. Darn, Craig why didnt you post the update sooner <HR></BLOCKQUOTE>
Sorry about that. I posted the info to my website the moment I noticed the problem and took the picture. I spend about 12 to 16 hours a day answering e-mail, around 1 to 2 hours taking pictures and typing web material, another hour filling orders, and anything left I spend here in Candlepower Forums or in front of my television set.
The differences I see between the Mini Trek and the PLW-3 with regards to battery contact wear are as follows:
The PLW-3 uses a stiff vertical copper strap to make contact with the copper plating on the bottom of the PCB. This strap quickly rubs a groove in the PCB, and rides in it like a train wheel on train tracks - carving itself deeper and deeper in the PCB every time you use the light.
The Mini Trek uses a piece of stiff wire to contact its PCB. The wear pattern is a series of shallow diagonal cuts in the solder of the PCB, rather than a continuous groove that's actually being cut into the board of the PLW-3.
So the potential failure mode is somewhat different, plus it should also take longer for the first symptoms to appear - if they appear at all.
It should be possible to rejuvenate a dead or dying PLW-3 by applying a thin layer of solder directly over the groove cut in the board by the battery contact. This should immediately restore operation, but the durability of such a repair is not yet known.
Because you are going to use a new PLW-3 insert in a Mini Trek, you will probably NOT experience the PLW-3's normal failure mode;
but instead you will see some diagonal marks appearing near the edge of the board after awhile. If these marks stay shallow, you may never experience any failure whatsoever.
When a PLW-3 murders itself, it's because of a sharp metal protrusion carving into the board
every time you turn the head. The Mini Trek's contact is a piece of wire laying horizontally on a small platform, and doesn't appear to be nearly as deadly or sharp; plus it rubs a larger surface area of the board at any given time, distributing the wear force over a greater area.
This may indeed be the "fix" that was needed for twist-on flashlights. But only time will tell for certain.
http://ledmuseum.home.att.net
------------------