Need advice on Surefire tailcap

[yazkaz]

I have a year 2006 Z58 tailcap, which is triple-tapped and has served me well all these years w/o any stuck clicky problem. I was able to unscrew the top cap in order to use the AW soft-start switch assembly.

Lately the switch boot has shown some wear so I set out to find replacement boots, but w/o luck. Contacted Surefire and was told switch boot is not separately available and that a replacement Z58 has to be issued. However, I have to return the older Z58 to the dealer for the new one, which I did.

Problem is, the newer Z58 (with white internals) is hard to hack open. For the older Z58, it took me less than five minutes of blowdrying to unscrew the top cap. But with the new Z58 it took me 25+ minutes of continuous blowdrying and yet the top cap didn't move a bit.

I've borrowed a friend's older-style Z58 which is brand new but has been subjected to seldom use. (This one has four taps I believe, and is a 07-08 model.) Despite having little lubrication the top cap unscrewed with ~3 minutes of blowdrying.

So now my question is: should I just return the new Z58 and ask for the Z58 w/worn-out boot back, or should I keep trying on the new Z58? If I can't open the Z58 then there's no way I can put back the soft-start switch in.

Also, is the newer Z58 w/white internals really better than the older ones w/silver metal plate, or otherwise?

Please advise!

 

[JBorneu]

I havn't done it myself, but I read somewhere here on CPF it helps to put the switch in a ziplock bag in boiling water for 10 minutes. Take care not to burn yourself.

 

[yazkaz]

I havn't done it myself, but I read somewhere here on CPF it helps to put the switch in a ziplock bag in boiling water for 10 minutes. Take care not to burn yourself.

The problem with zip-lock bags is that:
a. I don't have the necessary tools to hold/clamp the switch afterwards, which is said to be VERY hot by then;
b. the heat of the switch may be able to even melt a rubber of a strap wrench;
b. the zip-lock bag may melt prematurely, damaging the switch'es cosmetics and/or rubber boot.

I only have access to afford a pair of gloves, a rubber friction sheet, and a hair dryer. With these I was able to open up any older version Z58 -- but not this new one.

 

[Sgt. LED]

1 potholder will do to hold it. Anyway burns heal fast and a hacked tailcap will give you years of service.

You're just boiling it, not deep-frying it. Nothing will be harmed from that much heat.

Actual Zip-Lock brand bags will not melt down from boiling it for 5/10 minutes. Some types are even made to be boiled.

If you have gloves and a rubber friction sheet you should be almost done!
Besides, Surefire will not give your old one back. It's now theirs to be recycled.