Surefire MN11 Reflector Foam Tearing!

[Thundar]

I have a Surefire M3 that I tried to modify with a Cree R2. The LED module burned out and I'm going to put in an MN11 lamp.

When trying to put the MN11 (& MN10) reflector back in, I can't get it back in the shock isolation foam piece that loops around inside the head. The foam has started to tear in several places. Every time I try to push the reflector inside of the foam the foam either bows in so that the reflector is above the foam and the foam donuts downwards, or the reflector is at an angle and one side begins to donut downward. I literally struggled with it for 2 hours the other day.

I thought about putting glue on the outside of the foam, maneuvering the foam in place and letting the glue dry before attempting to put the reflector in. I'm concerned with the combination of heat and the glue, however...

Does anyone know if this glue/foam combination will light on fire or cause any kind of problem?

If this does present problems does anyone have any other ideas on how to get this in? Is there thinner foam that I've not found yet?

 

[allburger]

The reflector goes in before the foam does. Try that

 

[Thundar]

I'll give it a shot, thanks.

 

[Thundar]

OK. I tried putting the reflector in first and the foam tore even further. I'm assuming that I'm doing something wrong as putting the LED drop-in reflector in was much easier.

What I've been trying to do is place the foam ring between the outer lip of the reflector and the interior of the head.
Is this correct?
My foam strip is just barely in one piece now so any help would be appreciated.

 

[Thundar]

I'm thinking about taping the foam with electrical tape so that it at least stays together. I'll ask Lighthound if they have any foam strips tomorrow when I call them.

Is there any kind of foam I can use aside from what came in the light?

 

[Bullzeyebill]

Call SF and tell them that your foam is tearing. They will make it right, for free.

Bill

 

[Thundar]

Call SF and tell them that your foam is tearing. They will make it right, for free.

Bill

Good news. I will try that tomorrow morning. Thanks!

 

[DM51]

Call SF and tell them that your foam is tearing. They will make it right, for free.

They MAY agree to replace it, but their warranty does not oblige them to do that - the OP voided it when he took the head apart. These heads are sealed and not meant to be disassembled.

 

[Bullzeyebill]

DM51, yes, I was forgetting that head was taken apart. All of my repair requests to SF have not been the result of my tinkering with their light parts.

Bill

 

[Thundar]

I spoke with them this morning and they said I could send it in for a repair, but that they do not send out foam as the head is not supposed to be taken apart.

 

[Thundar]

Surefire put on an entirely new head for me, under a warranty-repair. They may not do the repair for non-LEO's if you've opened the head. I immediately spoke to a supervisor and advised I use it for duty and she got me an RMA. They also got the flashlight in and out of their system quickly.

I ordered an MN11 lamp from Lighthound... When I get it I will try to put up some beam photos with old/new lamp and with/without AW batteries... I still have to get on one of those picture hosting sites like PhotoBucket.com or ImageShack.us. Anyone have good experience with one?