Where to start?

[sinkhead]

Hi,

I have access to a fairly large lathe and I'd like to have a go at making a small, simple flashlight.

I've used the lathe before, but only for simple things. I know how to use it but I have absolutely no idea where to start when making a flashlight.

Any help, advice or suggestions appreciated.

Many thanks,

Sam.

 

[gadget_lover]

I find the place to start is with a drawing of the light. Then measure things like batteries, led stars, reflectors and switches to detrmine the tizes that you will be working with. Note all of those sizes on your drawings, adjusting things as necesary till everything fits.

In general you do not want to make things too thin. If you do not know how to create threads then you should practice first OR look at wats to put things together with press fits and screws.

Design it around your skills.

The next one you can use to practice new skills.

Daniel

 

[wquiles]

A good way would be to copy an existing light - something you can have there with you as you go along - something you can measure and compare against - something you can try the parts you are making, to make sure they fit. Perhaps a 1 or 2 cell, CR123 light would be ideal, since they are small but not tiny, and there are LOTS of lights that have those cells as a power source.

But since you said you have done fairly simple stuff on the lathe so far, I would suggest to "really" learn to do threads on the lathe, before you go further, as any/all lights will require some parts to be threaded, and threading is something that takes practice, so you don't want to practice with the first light you are making - you want to use some scrap pieces first

Please post pics of your progress and feel free to ask any questions you might have. And be careful with advice coming from Barry - his advice usually costing you money for new/better parts/accessories/etc. :naughty:

Will

 

[gadget_lover]

My first flashlight was made the way Will suggested.

I started with a 5LED Dorcy AA flashlight and built a body to replace the original. It fit the original head.

Then I made a head ( Lux I with optic) that would screw on the original body.

After that came a twisty tailcap, and then a twisty tailcap with a momentarty button, and finally an adapter that allowed me to use a Kroll clicky switch.

By the time I was done I was fairly good at measuring existing threads, matching sizes and getting a decent finish. I learned how to make many different kinds of mistakes. The picture is of the original light and the one that I made bit by bit.

I carried it as an EDC for a year or so before replacing it. It now does nightstand duty.

Daniel