Tom Anderson
Newly Enlightened
This was one of those projects that took a long time before even machining the first chip. I've always wanted to design an AAA driven flashlight that would compliment my titanium pens.
The idea kept burning in the back of my mind for years until I did more research and found what seemed to be an ideal platform to build from. With it's double cell power supply and CREE LED lamp technology, the Fenix™ LD05 penlight looked like it would fit the bill.
I recently ordered a pair of these (I always need 2 – just in case), and fiddled around with them for a few weeks until the project came up on my "to do list".
After taking one apart and looking at the fine threads and precision electronics inside, I decided to simply house one in titanium.
The project broke down into several main components:
1. A housing for the tip where the lamp is held.
2. A housing for the opposite end where the switch and pocket clip are located.
3. A housing to span the gap of the above two components.
4. A new switch button
5. A pocket clip (That was easy. I used the same clip as I put on my pens)
This arrangement was necessary due to the fact that trying to bore through 5" or so of 6AL4V titanium and remain on center and on tolerance would be extremely difficult on my old lathe using the cutters on hand. Even so, I found the difference between a light that works and a light that doesn't meant holding some pretty tight tolerances on all of the 3 housing components, as well as the new switch button.
The housing at the lamp was extended a bit to provide enhanced protection of the lens – especially important if there is any significant impact. I had to do some special machining in front of the lens to make sure the new housing didn't narrow down the beam too much.
Next, I machined the end housing where the switch and pocket clip are located. This extended the opposite end of the assembly by about 1/2", giving me room to drill and tap the pocket clip screw holes and installing an extension button that rides atop the factory switch. The issue of retaining the new button was resolved by cutting a blind groove in the side of the extension button and lengthening one of the pocket clip screws so it would ride in the groove. It took a bit of experimentation until I had everything fitted so the switch worked every single time.
With both ends now covered in titanium, the only thing left to do was to machine a titanium spacer to span the gap.
After getting all of the components machined and fit together, I put a little glue on them, and lined up the grooves and dots so it looked like my machining was intentional. For some reason, I needed to machine a little off the button again, but I finally have a light that works like it is supposed to work.
I'm sure a lot of this is "old hat" for the folks here on CPF, but it was a learning experience for me!
AAA Titanium Flashlight Specifications:
Base Model: Fenix™ LD05
Power: (2) AAA cells
Lamp: Cree XP-E (R2) LED
Operation: Push button switch
Lumens: 4 (low), 32 (medium), 100 (high)
Housing material: ø.750" 6AL4V titanium
Overall Length: 6 3/4"
Weight: 5.8 ounces (with batteries)
******************************
Keeping the dots and grooves aligned on the different components was a chore.
I machined descending dots on both the cap and the tip.
The button has cascading steps to promote a secure grip.
A little extra length at the tip protects the lens from dierect impact.
... and, yes, it even works!
The idea kept burning in the back of my mind for years until I did more research and found what seemed to be an ideal platform to build from. With it's double cell power supply and CREE LED lamp technology, the Fenix™ LD05 penlight looked like it would fit the bill.
I recently ordered a pair of these (I always need 2 – just in case), and fiddled around with them for a few weeks until the project came up on my "to do list".
After taking one apart and looking at the fine threads and precision electronics inside, I decided to simply house one in titanium.
The project broke down into several main components:
1. A housing for the tip where the lamp is held.
2. A housing for the opposite end where the switch and pocket clip are located.
3. A housing to span the gap of the above two components.
4. A new switch button
5. A pocket clip (That was easy. I used the same clip as I put on my pens)
This arrangement was necessary due to the fact that trying to bore through 5" or so of 6AL4V titanium and remain on center and on tolerance would be extremely difficult on my old lathe using the cutters on hand. Even so, I found the difference between a light that works and a light that doesn't meant holding some pretty tight tolerances on all of the 3 housing components, as well as the new switch button.
The housing at the lamp was extended a bit to provide enhanced protection of the lens – especially important if there is any significant impact. I had to do some special machining in front of the lens to make sure the new housing didn't narrow down the beam too much.
Next, I machined the end housing where the switch and pocket clip are located. This extended the opposite end of the assembly by about 1/2", giving me room to drill and tap the pocket clip screw holes and installing an extension button that rides atop the factory switch. The issue of retaining the new button was resolved by cutting a blind groove in the side of the extension button and lengthening one of the pocket clip screws so it would ride in the groove. It took a bit of experimentation until I had everything fitted so the switch worked every single time.
With both ends now covered in titanium, the only thing left to do was to machine a titanium spacer to span the gap.
After getting all of the components machined and fit together, I put a little glue on them, and lined up the grooves and dots so it looked like my machining was intentional. For some reason, I needed to machine a little off the button again, but I finally have a light that works like it is supposed to work.
I'm sure a lot of this is "old hat" for the folks here on CPF, but it was a learning experience for me!
AAA Titanium Flashlight Specifications:
Base Model: Fenix™ LD05
Power: (2) AAA cells
Lamp: Cree XP-E (R2) LED
Operation: Push button switch
Lumens: 4 (low), 32 (medium), 100 (high)
Housing material: ø.750" 6AL4V titanium
Overall Length: 6 3/4"
Weight: 5.8 ounces (with batteries)
******************************
Keeping the dots and grooves aligned on the different components was a chore.
I machined descending dots on both the cap and the tip.
The button has cascading steps to promote a secure grip.
A little extra length at the tip protects the lens from dierect impact.
... and, yes, it even works!
