Here's a simple mod that has huge rewards for a little work. This mod will install an MJLED into a Streamlight Key-Mate flashlight.
The stock Key-Mate (shown next a US Quarter) is very tiny and pretty bright in its own right, powered by four L1154 batteries, but the LED is always that 'angry blue' from being overdriven so much. We'll fix that color problem and increase the light output a whole bunch too.
The reflector and front lens are press fit in place. To remove them, use a socket to protect the black plastic LED holder and tap out with a hammer, or press out with an arbor press. Make sure the socket you use clears the threads completely or it will become wedged in the head. Place a paper towel or rag under the head assembly so the lens doesn't get scratched up.
Once the LED/Reflector assembly is removed from the head, we can begin the modification.
Carefully separate the reflector from the LED holder. Be careful not to bend the three legs on the back of the reflector too much or it will make re-assembly hard. Just pull and pry until they separate; it may be helpful to use a small screwdriver to pry with also.
Note that the lead going to the black post is the Negative lead. Unsolder the metal washer and set a side, it will be reused later. Take a moment and study how the LED leads are bent and formed on the LED holder. Remove the stock LED and replace with the MJLED forming the MJLED leads on the LED holder like the original leads were. Make sure the MJLED is seated in the LED holder like the original LED was. Remember the Negative (short) lead goes on the post, and the Positive (long) lead connects to the metal washer. Use solder wick if necessary to clean the small hole in the metal washer the LED lead goes into. Install the washer and trim off any excess lead length and solder the + lead to the metal washer.
Here's a picture of a stock assembly on the left, and one modded with an MJLED on the right. Re-install the assembled LED/Reflector into the flashlight head and press the lens in on top of it until it snaps in place.
Install the head on the battery tube and check for proper operation.
You now have a very tiny flashlight that puts out a huge amount of light for its size. Very bright side spill light with a nice bright spot in the center of the beam.
Here's the 'light saber' wall shot of the beam profile.
And that's all there is to this modification; you should be able to complete this in under an hour. The results compare very favorably against the Nano-Mate running a Micro-converter and Luxeon LED.
Lambda
The stock Key-Mate (shown next a US Quarter) is very tiny and pretty bright in its own right, powered by four L1154 batteries, but the LED is always that 'angry blue' from being overdriven so much. We'll fix that color problem and increase the light output a whole bunch too.
The reflector and front lens are press fit in place. To remove them, use a socket to protect the black plastic LED holder and tap out with a hammer, or press out with an arbor press. Make sure the socket you use clears the threads completely or it will become wedged in the head. Place a paper towel or rag under the head assembly so the lens doesn't get scratched up.
Once the LED/Reflector assembly is removed from the head, we can begin the modification.
Carefully separate the reflector from the LED holder. Be careful not to bend the three legs on the back of the reflector too much or it will make re-assembly hard. Just pull and pry until they separate; it may be helpful to use a small screwdriver to pry with also.
Note that the lead going to the black post is the Negative lead. Unsolder the metal washer and set a side, it will be reused later. Take a moment and study how the LED leads are bent and formed on the LED holder. Remove the stock LED and replace with the MJLED forming the MJLED leads on the LED holder like the original leads were. Make sure the MJLED is seated in the LED holder like the original LED was. Remember the Negative (short) lead goes on the post, and the Positive (long) lead connects to the metal washer. Use solder wick if necessary to clean the small hole in the metal washer the LED lead goes into. Install the washer and trim off any excess lead length and solder the + lead to the metal washer.
Here's a picture of a stock assembly on the left, and one modded with an MJLED on the right. Re-install the assembled LED/Reflector into the flashlight head and press the lens in on top of it until it snaps in place.
Install the head on the battery tube and check for proper operation.
You now have a very tiny flashlight that puts out a huge amount of light for its size. Very bright side spill light with a nice bright spot in the center of the beam.
Here's the 'light saber' wall shot of the beam profile.
And that's all there is to this modification; you should be able to complete this in under an hour. The results compare very favorably against the Nano-Mate running a Micro-converter and Luxeon LED.
Lambda
