 |
Thanks to "Ron" from CandlePowerForums for the
idea and helpful hints!
Note: This light actually runs on 2-AAA batteries,
the other 2 simply double the run-time of the light..
This modification removes the bulb from a 4-AAA Energizer
Double Barrel flashlight and replaces it with a Luxeon Star
LED module. Luxeon Stars are available from Arc
Flashlight. 3 things needed to be accomplished for this
mod: 1) Trim reflector to fit over LS module; 2) Trim LS module
board to fit in head; 3) support LS module inside head of
light.
|
|
1) Trim reflector to fit over LS module
You have 2 options, remove the reflector completely or use
a Dremel tool to grind out the reflector so the large LS optics
would fit through. I took the second option (yes, I was finally
able to buy a Dremel!) and used High Speed Cutter bit # 117
to remove the material until the LS fit through the hole.
|
 |
 |
Face-on shot of the bored out reflector - this took a lot
of time as the plastic reflector is very thick. As you can see,
the Dremel does fine work. The inner "ring" on the
lens is marring caused by the LS lens pressing against the flashlight
head lens. |
|
2) Trim the LS board to fit in the head
Again I used the Dremel, this time with a Structured Tooth
Tungsten Carbide Cutter bit # 9931. I carefully trimmed around
the edges until the LS fit in the head of the light. I did
a little touch-up with a fine file to clean up the edges.
The LS is plugged into the old bulb socket with tinned-end
solid copper wire soldered to the LS.
|
 |
 |
3) Support the LS in the head on the light
For this I figured I had 2 options - Glue the LS DOWN, or
push the LS UP. I chose to push it up against the lens of
the light, thereby making sure it was both level and removable.
The LS marrs the inside of the flashlight lens where it rubs
when tightening the head, but you don't see the marks with
the LS in there and it does not affect light output.
|
| I picked up a spring at Lowes and modified the shape with
2 pair of pliers by carefully bending it to fit my needs. |
 |
 |
Here are the resulting beams - this is my first attempt at
taking beam pictures. LS on the left, 2-AA Mini-Mag with a Nexstar
Xenon bulb on the right. The Mini-Mag is a touch brighter and
has a larger aurora which cannot be seen in these shots. |
