RepProdigious
Enlightened
I got a couple questions on how i built this little mag;
so here's a write-up on this relative simple build:
NEEDED PARTS:
-D-Maglite
-Go to dealextreme for a copper board XML (SKU 54704)
-Go to KD for a mag cam MOP reflector (Id:1739 - SKU: S004023) and a 2800mA driver board (Id=10995 - SKU: S009742) (in most pictures here you will see the SMO reflector but that sucks with the xml, i had to mist it to MOP myself to get a decent beam profile)
-Get a GOOD lens (flashlightlens.com has some nice stuff, thats where i got mine)
-Go to your diy store to get a solid copper slug (or brass) to fit inside the KD reflector cam (tight press-fit is best), you can also make a P60 base to fit (like i did)
-Find some STRONG 2 component metal glue
-Get some solarforce or alike complete tail-assembly
-Get some arctic silver epoxy and normal paste
Now put everything together:
-Disassemble mag, toss the lens, light holder/switch assembly
-Cut the mag-tube, if like me you don't have a lathe, go like this this:
So cut (red lines in pic) the middle part out. On the head-side just behind the groove for the o-ring and on the tail-end just on the length you want. Then, grind the inside of the cut tail-end so the o-ring groove fits in there barely (a tight press-fit is best, dont forget to also sand the head part where the o-ring sat a bit for good electrical contact) and then press and glue together with the best 2 component metal glue you can find. You will now need a new thinner o-ring because it will now sit at the base of the threads instead of the (now re-purposed) o-ring groove.
Drill holes in the copper/brass base slug for the wires to go through (p60 base has these already), solder the XML board to the center, feed wires through holes and epoxy the driver board to the back of the slug. Epoxy the slug in the cam (with the cam cut down straight about half-way). Screw the cam on the reflector with plenty heat paste (tighten hard for good electrical contact) and put the reflector assembly in the head with again plenty heat paste where they meet. I found that this is enough heat-sinking for the XML to burn through two full 18650's on max without the temperature at the slug exceeding 50 celsius at room temperature with the outside of the head always keeping within 5 degrees of the slug temperature... so thats a pretty good thermal path.
Now comes a tricky part, you need to make a connection between the top of the new shortened tube to the reflector. I just took an old MAG spring and bent this in the same diameter as the tube, then sand down the top of the tube where it will meet the spring. Works brilliantly. Unfortunately i didn't take any pictures there...... here's a quick drawing on the idea:
Yellow is the reflector, blue is the led/driver/slug, grey is the tube and the red dots is where the spring sits to complete the circuit between the tube and the driver (through the reflector)
Okay, now take the solarforce tail assembly and maglite tail, and take apart. Drill a bid ol hole in the mag tail (about the size of the rubber boot on the solarforce tailcap) file/grind down the solarforce tail so the button sits flush.
Make the inside of the solarforce tailcap sit flush with the bottom of the mag spring.
When you are satisfied with everything sand down the inside of the mag tail and again put your super metal epoxy to use and make the two tails one, keep the parts pressed together as the glue sets (to make sure its water-tight and strong and to ensure electrical contact).
Well, that should just about cover it all.. let me know if there's anything i let out! You should now have a short D-mag with a stock head that can be completely disasembled like any mag should and also an easy to replace clicky (makes for easy to source replacement parts).
This light works brilliantly on any big li-ion cell (i use 18650 in a plastic tube and have some big fat cells on route) and you can also run this baby on eneloops!!
And this is what my reflector currently looks like after a quick SMO->MOP mod:
I hope you guys like!
so here's a write-up on this relative simple build:
NEEDED PARTS:
-D-Maglite
-Go to dealextreme for a copper board XML (SKU 54704)
-Go to KD for a mag cam MOP reflector (Id:1739 - SKU: S004023) and a 2800mA driver board (Id=10995 - SKU: S009742) (in most pictures here you will see the SMO reflector but that sucks with the xml, i had to mist it to MOP myself to get a decent beam profile)
-Get a GOOD lens (flashlightlens.com has some nice stuff, thats where i got mine)
-Go to your diy store to get a solid copper slug (or brass) to fit inside the KD reflector cam (tight press-fit is best), you can also make a P60 base to fit (like i did)
-Find some STRONG 2 component metal glue
-Get some solarforce or alike complete tail-assembly
-Get some arctic silver epoxy and normal paste
Now put everything together:
-Disassemble mag, toss the lens, light holder/switch assembly
-Cut the mag-tube, if like me you don't have a lathe, go like this this:
So cut (red lines in pic) the middle part out. On the head-side just behind the groove for the o-ring and on the tail-end just on the length you want. Then, grind the inside of the cut tail-end so the o-ring groove fits in there barely (a tight press-fit is best, dont forget to also sand the head part where the o-ring sat a bit for good electrical contact) and then press and glue together with the best 2 component metal glue you can find. You will now need a new thinner o-ring because it will now sit at the base of the threads instead of the (now re-purposed) o-ring groove.
Drill holes in the copper/brass base slug for the wires to go through (p60 base has these already), solder the XML board to the center, feed wires through holes and epoxy the driver board to the back of the slug. Epoxy the slug in the cam (with the cam cut down straight about half-way). Screw the cam on the reflector with plenty heat paste (tighten hard for good electrical contact) and put the reflector assembly in the head with again plenty heat paste where they meet. I found that this is enough heat-sinking for the XML to burn through two full 18650's on max without the temperature at the slug exceeding 50 celsius at room temperature with the outside of the head always keeping within 5 degrees of the slug temperature... so thats a pretty good thermal path.
Now comes a tricky part, you need to make a connection between the top of the new shortened tube to the reflector. I just took an old MAG spring and bent this in the same diameter as the tube, then sand down the top of the tube where it will meet the spring. Works brilliantly. Unfortunately i didn't take any pictures there...... here's a quick drawing on the idea:
Yellow is the reflector, blue is the led/driver/slug, grey is the tube and the red dots is where the spring sits to complete the circuit between the tube and the driver (through the reflector)
Okay, now take the solarforce tail assembly and maglite tail, and take apart. Drill a bid ol hole in the mag tail (about the size of the rubber boot on the solarforce tailcap) file/grind down the solarforce tail so the button sits flush.
Make the inside of the solarforce tailcap sit flush with the bottom of the mag spring.
When you are satisfied with everything sand down the inside of the mag tail and again put your super metal epoxy to use and make the two tails one, keep the parts pressed together as the glue sets (to make sure its water-tight and strong and to ensure electrical contact).
Well, that should just about cover it all.. let me know if there's anything i let out! You should now have a short D-mag with a stock head that can be completely disasembled like any mag should and also an easy to replace clicky (makes for easy to source replacement parts).
This light works brilliantly on any big li-ion cell (i use 18650 in a plastic tube and have some big fat cells on route) and you can also run this baby on eneloops!!
And this is what my reflector currently looks like after a quick SMO->MOP mod:
I hope you guys like!
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