Simple First Mod - "Dopalec"

[Tomas]

I ordered a BB400 yesterday, and needed to either free up one of my two Opalec / *ini*ag units, or get another *ini*ag.

As I was rolling through Sear's tool department today, I happened to spot an aluminium Sears Craftsman double AA mini. I stopped and looked it over, really liked the switch (!) and decided that one way or another an Opalec could be stuffed in to it.

In order to get the Opalec seated deeply enough, I routed out some of the plastic in the top of the barrel that was blocking it, and also removed about 1mm from the bottom skirt of the Opalec (Dremel). That 1mm was removed in a ring around the bottom leaving the raised portion in the center untouched.

Oh, yeah, those two plastic pins on the bottom of the Opalec had to go.

I fit perfectly, and since there was nothing to hold it in place other than the electrical connection pins, I epoxied it into the top of the barrel with a 5 minute epoxy.

The reflector and lens in the head are a press fit. FIRST one must pull the reflector toward the back of the head to get it out of the lens casting, then the lens casting can be pushed out the front of the head, followed by the reflector falling out. I put the lens back in, and put it on the barrel and the light worked like a champ.

Initially the lens pressed against the front of the LEDs, but I found that I could put a thin washer (it was in my junk box - I have no idea what it came from: The OD was the right size to rest against the ridge formed by the back of the lens casting, and the ID fit around the LED's and wouldn't let the body of the Opalec through.

Separation of the LEDs from the lens is now about 0.5mm. Perfect.

The flashlight (34-93112) came with two krypton bulbs, two alkaline AA cells, and quite a nice sheath all for US$9 ...

It's not much of a mod, really, but it made a nice light that will probably get a lot of use, and I love the switch.

The old *ini*ag is now patiently waiting for the BB400.

ADDED: I was informed a bit later in this thread that the Sears flashlight is a Dorcy, hence the name for the Dorcy / Opalec: Dopalec.

T

 

[Daniel Ramsey]

I would grade that as an A for a mod, good work!

 

[B@rt]

Looks nice Tomas.

How much longer is the light than a *ini*ag?
Thanks,

 

[Tsao]

hi Tomas
Your light is so beautiful. :up
I had made a guick search on google, I can't find any 2AA Craftman. Am I missing something?
The pic shows the coating is not like the mini mag, mini mag seems like much better. I like the way of switch this light. Not much AA size got this kind switch.

 

[McGizmo]

Tomas,

Great job! This doesn't look like a mod, rather a professional offering! Thanks for sharing a great idea!

- Don

 

[evan9162]

Oh! That looks exactly like the Dorcy 2AA aluminum I picked up from Ace hardware a few weeks ago. Sears probably contracted with Dorcy for those. (I'll post a picture tonight if I remember).

The pushbutton switch is nice for mods - An NX05 luxeon collomator fits almost perfectly in the head.

-Darin

 

[Tomas]

To answer some of the comments ...

The Craftsman flashlight is one inch longer than the *ini*ag AA, and is an anodized aluminium case. The rack at the store had them in red, green, black, dark blue, and "champagne."

The finish on the Sears light and the newer *ini*ags appears to be about the same quality, but the *ini*ags have a smooth polished exterior while this one has a rather "grippy" finish. The lathe marks are still there and offer a nice evenly spaced bunch of very shallow, wide "grooves" that MAY have been lightly bead blasted before anodizing.

As to this light possibly being a Dorcy 2AA, It likely is. Since there's an Ace hardware 2 blocks from home I'll wander by and take a look.

Lastly, if the NX05 looks like a good fit, I'm going to see if the BB400 that's in transit to me can be coerced into living happily in this type of light. If so, my old *ini*ag may have to wait even longer for someting to fit into it.

If the BB400 can be fitted well into this type of flashlight, I can see I'm going to have to buy another flashlight to convert to the real light: LED - I like that switch.

Thanks for all the comments, folks!

Take care,

 

[evan9162]

Here's my Dorcy:

Pretty much the same thing

Though this guy's getting a LS

-Darin

 

[Bushman]

Do you guys have any trouble with the switch being intermittent? Lambda was going to use these forthe illuminator project but abandonded them b/c the switch was a bit finiky.

 

[Tomas]

Yup, Darin, that's the same basic shell, right down to the flip-out stainless steel ring at the tail.

If I do manage to stuff a 1W LS into one of these, one of my requirements will be a replacement lens that has more quality and durability. It's not that I don't take care of my stuff, it's just that "bad things happen to good lights" sometimes.

Lemme know how you do shoehorning in an LS, eh?

Take care,

 

[Slick]

Nice first mod, Thomas

Bushman - I just recently bought a Craftsman that had a "touchy" switch from a really cool fellow CPF'er. I found that it could be disassembled by using a bamboo skewer inserted via the batterytube and held against the bottom side of the tube opposite the switch button and pushing forwards. This forces half of a "clamshell" type brace out that holds the switch in. The switch then drops down and slides out the front of the battery tube. After the switch is out, the rubber cover can be removed and the switch then cleaned using WD40 to restore perfect operation..

This lonely Craftsman is now pining for it's Red/Orange Luxeon emitter that is on backorder from Future...

 

[NightShift]

About what voltage does the opalec's red light go on and the light starts to dim?

The batteries are fairly new when I have been using it, and I knocked the mag off a table no more than 3 feet high and it hit the floor (ouch). I turned it on to check it and it's dim and the red light is on. The batteries each measure 1.45V. Could that have damaged the module? I put two newer batteries in it (1.6 & 1.5V) and it's fine.

(EDIT:) Forget it, I just tried 2 Ni-MH's @ 1.2V ea. and it worked fine. I also tested the dropped batteries under load and they went from 1.4V down to .3 and .7V....Whew!

I was starting to doubt Opalec's advertisement "Highly shock-resistant"...how silly of me

 

[evan9162]

Not to steal the spotlight, but here's a quick glimpse of the Dorcy mod in progress:

The disk on the screw is the copper disk/plate that I'm mounting the emitter to. That will fit snugly inside the tube. It's on a screw so I can trim it down with a power drill and file (poor mans lathe). Everything is kind of on hold, since both my drill batteries are dead

I've trimmed the switch about 3/16" back to make room for things.
-Darin

 

[Tomas]

Looks like a nice start to the project.

I see you use the same custom metal lathe I do for precision work on special projects ...

How's the fit of the optical assembly in the Dorcy head?

I "happened" to have my Dorcy 2AA / Opalec conversion with me yesterday when I ran into the building maintenance guy trying to see something using his *ini*ag. I whipped out my "Dopalec" and handed it to him, and when he was through he asked where he could get one.

I told him it was a conversion I'd whipped up the day before in my bedroom. I even "borrowed" his weak *ini*ag batteries to show him that my Dopalec got more light out of batteries. It popped on full brilliance whereas his *ini*ag was just a cheery orange glow with 'em.

I strongly suspect that I'll be trying to wedge my BB400 into service in another Dorcy when the '400 gets here. I have some ideas for assuring heat dissipation assuming I can fit the sandwich in.

Keep letting us know how your "Dorstar" conversion is working out, eh?

 

[evan9162]

Or perhaps "Dorlux?"

The optic is < 1/2mm diameter smaller than the inside of the head

I think I have a solution: The flat front surface of the NX05 is raised a bit. The diameter of that surface fits exactly within the original clear plastic lens peice. That is, it's the same diameter as the original reflector.

I'm going to make a ring out of part of the clear lens - that will keep the optic centered perfectly, and allow me to possibly glue it into the right spot.

As I discovered this morning, the LS is Q3M binned - meaning 30-40 lumens, and 3.03-3.27V

Showing off LED flashlights is always fun

-Darin

 

[Tomas]

Sounds good!

The fit into the original lens ring could make things a bit easier, assuming you can route the original lens out of the way.

Sounds like you have an excellent LS there!

 

[Rothrandir]

q3m...*drool*

i order the emitters so i never know what bin i get...probably not that high though...

 

[EMPOWERTORCH]

The base torch looks very much like a torch on sale at Maplin which is also available as a 3AA torch with the same head and tail...a good torch to mod with multiple InGaN nichias or a cyan Luxeon!
Price is £4.99!

 

[StuU]

I have couple of these Craftsman 2AA lights. I wasn't sure what to do with them...maybe a hot red light with 4 or so 8,000mcd agilent reds? With the switch module removable it should be possible to open up a solid soldering base on the twin bulb contacts. Should be pretty bright...in fact, just one of these 8,000mcd reds is pretty bright!

 

[shankus]

Re: Simple First Mod - \"Dopalec\"

Are there any updates with regards to putting a BadBoy or MadMax into one of these Craftsman/Dorcys?