This post was returned to the thread on 2/8/06.
Alrighty you guys. Here are the directions for making the Mag85. Let this be the official "Mag85" modding thread. Please feel free to post your own experiences with this mod. The MagCharger Bi-pin Slug Mod (BP) is described in detail below the main mod.
Parts:
0. Flashlight: Duh, it's a Mag mod so go get yourself a Mag 3D in any color you like.
1. Bulb: Welch Allyn WA01185, 9.6V, 3.15A spec. If you are using the MagCharger bi-pin slug drop-in mod, you can use the bare, unpotted bi-pin bulb as-is. This bulb is commonly available a) from CPF supporting vendor LightEdge, b) direct from Welch Allyn after a $100 minimum purchase requirement is met or c) through a Group Buy such as recently organized by S4MadMan.
2. Reflector: There are multiple ways to skin the cat but the easiest is to wait until mid-late February for CPF super-modder Fivemega to post that his latest batch of cammed, aluminum Mag replacement reflectors are for sale. I think this will be in the B/S/T forum so keep your eyes peeled.
3. Lens: Go to CPF supporting vendor Flashlightlens.com and order up some of his UCL (Ultra Clear Lens) or the tougher but marginally lower transmission Borofloat upgrade lenses.
4. Battery Carrier: The Mag85 mod, in its classic form, uses 9 x AA nimh. To handle these in your Mag body, you'll need a battery carrier that arranges these cells neatly in a circuit. Your best bets are a) Elektrolumens' 3-D battery adapters. We are waiting to hear about the next production run but when they become available, get yourself three of 'em. b) Fivemega's ultra gnarly 9AA-3D adapter. As with the Fivemega reflectors, keep your eyes peeled on the B/S/T forum.
5. Batteries: Through extensive testing and use, I've found that anything from 1800mAh to 2300mAh cells will work. However, if you want the optimal balance of runtime and brightness, 2100mAh cells are your best bet. My personal favorites are the Sanyo/Energizer 2100mAh cells.
6. Bulb Socket: If you plan to use the bare bi-pin bulb (this is the most flexible option) then you'll need to score yourself a replacement bi-pin slug receiver from a MagCharger switch assembly. I buy mine from Cases4Less and their part number is ML-108-106 which costs $10.50.
That's all. Directions are as follows.
1. Unscrew the front face cap and replace the stock plastic lens with the Flashlightlens upgrade glass. Screw the face cap back on. make sure the O-rings are seated properly and do not screw down too hard or you risk cracking your lens. Note: The face cap is the ring at the very front of the light that has writing on it.
2. Then, replace the stock plastic reflector with the Fivemega aluminum upgrade unit. Screw back on the face cap and then unscrew the entire head.
3. While the head is off, plug in the bulb. If using the BP mod, stick the bulb pins into the two holes as far down as they will go. It might be useful to carefully clip off 2mm from the end of the pins to help focus. If using a potted bulb, simply replace the bulb as you normally would. Note: When reinstalling the head, I find that 2-3 wraps of teflon pipe thread tape around the threads eliminates head wobble and helps maintain good bulb/reflector centering.
4. Stuff the batteries in the battery holder of your choice. Double and triple check for correct battery orientation. Remove the tailcap and load the battery carrier(s) into the torch. Before you do this, though, make sure the switch is in the "off" position.
5. Push the switch and bask in the 1,200 lumen (800 lumens out the front) glow of a genuine superlight that you've just assembled yourself!
The MagBP mod
These are the directions for extracting the bi-pin slug from a MagCharger switch assembly and installing it in a regular Mag.
1. Push down slightly on the spring loaded bi-pin bulb socket on the MC switch assembly. Then, using a 5/64" (2mm) hex wrench, remove the two brass-colored cam bolts from the sides of the "snout" at the front of the MC switch assembly.
2. Slide the slug out the front of the switch assembly. The plastic slug is snugged inside a heavy metal sleeve. These are the two parts you'll use in this mod. You will not need the spring, little cup or anything else from the MC replacement switch.
3. Take your Mag and remove the rubber switch boot by prying it up with a fingernail. Remove the tailcap now as well. Push the switch to the depressed "on" position.
4. Insert the hex wrench into the small hole in the center of the button plunger. Seat the wrench and start unscrewing. When you can move the switch backwards in the body tube, try pushing the switch out the back of the light. If it doesn't come out, unscrew by half-turns until it slides right out.
5. Insert the hex wrench into the brass-colored cam bolt on the front of the Mag switch and remove.
6. Slide out the bulb holder and heavy metal sleeve. Set this aside so you can replace it if needed. Make sure the spring and small, flat metal cup are still seated inside the switch. Take the small metal cup from the rear of socket/sleeve and insert it into the back of the MC slug/sleeve.
7. Insert the MC slug/sleeve into the Mag switch assembly making sure the spring goes up into the back of the metal cup. IMPORTANT: Make sure the thin metal strip inside the plastic pedestal is sliding on the outside of the slug/sleeve.
8. Press the slug down and align the hole for the cam bolt with the slot in the plastic stem of the Mag switch. Screw in the cam bolt you removed in step 5.
9. Slide the entire switch back into the Mag, align and center the switch plunger in the hole in the body. Using the hex wrench, tighten the pointy set screw locking the switch assembly in place.
10. Stuff the rubber switch boot back in place and you're all done.
Note: These directions do not cover the older Mag models which require a special spanner wrench to remove the switch assembly. This step would occur before step 4 above.
Wilkey
Alrighty you guys. Here are the directions for making the Mag85. Let this be the official "Mag85" modding thread. Please feel free to post your own experiences with this mod. The MagCharger Bi-pin Slug Mod (BP) is described in detail below the main mod.
Parts:
0. Flashlight: Duh, it's a Mag mod so go get yourself a Mag 3D in any color you like.
1. Bulb: Welch Allyn WA01185, 9.6V, 3.15A spec. If you are using the MagCharger bi-pin slug drop-in mod, you can use the bare, unpotted bi-pin bulb as-is. This bulb is commonly available a) from CPF supporting vendor LightEdge, b) direct from Welch Allyn after a $100 minimum purchase requirement is met or c) through a Group Buy such as recently organized by S4MadMan.
2. Reflector: There are multiple ways to skin the cat but the easiest is to wait until mid-late February for CPF super-modder Fivemega to post that his latest batch of cammed, aluminum Mag replacement reflectors are for sale. I think this will be in the B/S/T forum so keep your eyes peeled.
3. Lens: Go to CPF supporting vendor Flashlightlens.com and order up some of his UCL (Ultra Clear Lens) or the tougher but marginally lower transmission Borofloat upgrade lenses.
4. Battery Carrier: The Mag85 mod, in its classic form, uses 9 x AA nimh. To handle these in your Mag body, you'll need a battery carrier that arranges these cells neatly in a circuit. Your best bets are a) Elektrolumens' 3-D battery adapters. We are waiting to hear about the next production run but when they become available, get yourself three of 'em. b) Fivemega's ultra gnarly 9AA-3D adapter. As with the Fivemega reflectors, keep your eyes peeled on the B/S/T forum.
5. Batteries: Through extensive testing and use, I've found that anything from 1800mAh to 2300mAh cells will work. However, if you want the optimal balance of runtime and brightness, 2100mAh cells are your best bet. My personal favorites are the Sanyo/Energizer 2100mAh cells.
6. Bulb Socket: If you plan to use the bare bi-pin bulb (this is the most flexible option) then you'll need to score yourself a replacement bi-pin slug receiver from a MagCharger switch assembly. I buy mine from Cases4Less and their part number is ML-108-106 which costs $10.50.
That's all. Directions are as follows.
1. Unscrew the front face cap and replace the stock plastic lens with the Flashlightlens upgrade glass. Screw the face cap back on. make sure the O-rings are seated properly and do not screw down too hard or you risk cracking your lens. Note: The face cap is the ring at the very front of the light that has writing on it.
2. Then, replace the stock plastic reflector with the Fivemega aluminum upgrade unit. Screw back on the face cap and then unscrew the entire head.
3. While the head is off, plug in the bulb. If using the BP mod, stick the bulb pins into the two holes as far down as they will go. It might be useful to carefully clip off 2mm from the end of the pins to help focus. If using a potted bulb, simply replace the bulb as you normally would. Note: When reinstalling the head, I find that 2-3 wraps of teflon pipe thread tape around the threads eliminates head wobble and helps maintain good bulb/reflector centering.
4. Stuff the batteries in the battery holder of your choice. Double and triple check for correct battery orientation. Remove the tailcap and load the battery carrier(s) into the torch. Before you do this, though, make sure the switch is in the "off" position.
5. Push the switch and bask in the 1,200 lumen (800 lumens out the front) glow of a genuine superlight that you've just assembled yourself!
The MagBP mod
These are the directions for extracting the bi-pin slug from a MagCharger switch assembly and installing it in a regular Mag.
1. Push down slightly on the spring loaded bi-pin bulb socket on the MC switch assembly. Then, using a 5/64" (2mm) hex wrench, remove the two brass-colored cam bolts from the sides of the "snout" at the front of the MC switch assembly.
2. Slide the slug out the front of the switch assembly. The plastic slug is snugged inside a heavy metal sleeve. These are the two parts you'll use in this mod. You will not need the spring, little cup or anything else from the MC replacement switch.
3. Take your Mag and remove the rubber switch boot by prying it up with a fingernail. Remove the tailcap now as well. Push the switch to the depressed "on" position.
4. Insert the hex wrench into the small hole in the center of the button plunger. Seat the wrench and start unscrewing. When you can move the switch backwards in the body tube, try pushing the switch out the back of the light. If it doesn't come out, unscrew by half-turns until it slides right out.
5. Insert the hex wrench into the brass-colored cam bolt on the front of the Mag switch and remove.
6. Slide out the bulb holder and heavy metal sleeve. Set this aside so you can replace it if needed. Make sure the spring and small, flat metal cup are still seated inside the switch. Take the small metal cup from the rear of socket/sleeve and insert it into the back of the MC slug/sleeve.
7. Insert the MC slug/sleeve into the Mag switch assembly making sure the spring goes up into the back of the metal cup. IMPORTANT: Make sure the thin metal strip inside the plastic pedestal is sliding on the outside of the slug/sleeve.
8. Press the slug down and align the hole for the cam bolt with the slot in the plastic stem of the Mag switch. Screw in the cam bolt you removed in step 5.
9. Slide the entire switch back into the Mag, align and center the switch plunger in the hole in the body. Using the hex wrench, tighten the pointy set screw locking the switch assembly in place.
10. Stuff the rubber switch boot back in place and you're all done.
Note: These directions do not cover the older Mag models which require a special spanner wrench to remove the switch assembly. This step would occur before step 4 above.
Wilkey
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