Surefire KL5/KL3/KL1 mods

Boltgun

Newly Enlightened
Joined
Oct 11, 2004
Messages
171
Location
Nova Scotia, Can
Hi guys...I spent the better part of about 2 hours searching and kind find what I am looking for......HELP!

I need any threads or advice on breaking seals on the A/M led heads so that I can do some modding. I already scored my KL5 trying to heat it and turn it in a vise and th eonly thing that came loose was the front ring! I wasn't even heating the front!

Anyways, any help is apprecaiated.

TIA

Boltgun
 
I used a peice of 2 X 4 that I used a hole saw to drill a hole slightly smaller than the diameter of the head to hold the head in a vise. I then use heat and a chain wrench with a rubber tire tube to protect the Ano. and most heads unscrew.

I did however have a PAIN IN THE A$$ trying to get a newer style KL3 apart and ended up completely destoying it! That the only head I haven't been able to get apart.....so far
 
You need a pair of good strap wrenches, a miniature gas torch and a lot of patience.

When you heat up the bezel, stop heating when the temperature reaches 160 °C, which will soften even the stonger loctite. Above that temperature, the aluminium reflectors will delaminate, and the electronic parts will deteriorate, especially capacitors.
At 180 °C, the o-rings will start melting, and the dome of any LED inside will pop.
I use a K type termocouple probe for temperature measuring. I'm planning to buy an IR thermometer for opening lights.
If the bezel contains a plastic reflector, or a plastic coated reflector (like the Fenixes) please stop at 100 C. Many CPFers boils the bezel in a plastic bag to be sure not go above 100 °C. It doesn't always work, since 100 °C is not enough to softens all four type of loctite.
For about 10 minutes, keep the bezel at 160 °C, still providing some heat. The loctite requires some time at high temperature before it softens.
While the bezel is still hot, engage it in the strap wrenches. It will open.

While my description can sound simple, handling a hot bezel is not. Wearing mittens can be an idea; also protective goggles, since glass windows may shatter. Alignment of strap wrenches is essential, and another person helping out can be useful.
Consider that nat HAIII will get slightly clearer after such operation.
Also, if you try to open Fenixes, you need some extra practice since the walls are tiny, there is very little grip, and their loctite is the "definitive" one, and is not color coded as "our" loctite; in addition, the reflectors are made of polyester coated aluminium. The coating is very temperature sensitive.
Consider that some combinations of finer threads and excess of loctite (or epoxy) may render a light unopenable; a typical examble being the Arc4.
In my experience, 70% of the openings have been successful. The other 30% is in my "horror box" - the most expensive collection of garbage I ever produced.

Hope this helps

Anthony
 

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