Surefire KL3 Head Modification

[Bub8731]

I have a KL3 that I want to modify with a modern LED and driver. I have been able to get past the red loctite on the bezel but the glass won't move and the back side is inaccessible to my snap ring pliers. I am considering breaking the glass and buying a replacement from lumensfactory. Any advice on how to proceed?

 

[F89]

If you can upload a few decent photos to show where exactly you're up to, I can probably give you some advice.

 

[Bub8731]

If you can upload a few decent photos to show where exactly you're up to, I can probably give you some advice.

The front shows the bezel removed and the back shows the 4 holes which I assume are for some kind to tool to latch onto and thread it out which I am unable to reach.

 

[F89]

You need to remove the pill from the back of the head. I'd stay away from the lens end unless you've already damaged it.
I know you said that you can't reach it but you'll need to heat the head to soften the thread locker and use some sort of pliers to remove the pill (from the back of the head.

Below is a picture from a Japanese website which may be helpful.

I've seen a couple of different mods on this head. Some involved the machining of custom heat sinks (triple) and modification for the use of P60.
Personally I think I could use the existing pill and do either a single LED with a reflector or TIR, or even a triple using a copper MCPCB and H17Fx driver.
The P60 route would be pretty simple if all else failed.

I will say that while I've modified a variety of Surefire lights, I haven't done this one.

 

[Bub8731]

You need to remove the pill from the back of the head. I'd stay away from the lens end unless you've already damaged it.
I know you said that you can't reach it but you'll need to heat the head to soften the thread locker and use some sort of pliers to remove the pill (from the back of the head.

Below is a picture from a Japanese website which may be helpful.


View attachment 64630

I've seen a couple of different mods on this head. Some involved the machining of custom heat sinks (triple) and modification for the use of P60.
Personally I think I could use the existing pill and do either a single LED with a reflector or TIR, or even a triple using a copper MCPCB and H17Fx driver.
The P60 route would be pretty simple if all else failed.

I will say that while I've modified a variety of Surefire lights, I haven't done this one.

Thank you so much for the info! That picture is exactly what I was looking for. I will probably try to stick an H17fx driver in there.

 

[BU2(SCW)]

Your project may be done by now, but If it is not too late. A camera lens disassembly tool may likely be your best option for unthreading the back. They allow for a great deal of reach and have narrow tools for fitting between the spring and body.

I have a few of these I would like to mod and have just started looking into this.

As stated above I would apply a good amount of heat to the outside alluminum before trying to remove the assembly from the rear.

 

[Monocrom]

Your project may be done by now, but If it is not too late. A camera lens disassembly tool may likely be your best option for unthreading the back. They allow for a great deal of reach and have narrow tools for fitting between the spring and body.

THIS.
An excellent idea.

 

[tx101]

I think the lens is stuck to the gasket underneath it.
When I modded my KL3, samething happened to me. The lens is very thick and very brittle so do not use anything metal to pry it off.

I did my KL3 a while back so my memory is a tad sketchy but is there a thin oring sitting on top of the lens as well ?

I used Blu-Tack to pop off the lens. Just use a blob of it, jam it against the lens, twist it around and then pull. That should get it off.