This mod/circuit is supplied in its entirety by Ned K. Thanks Ned!

Coleman Flashlight with Luxeon Star

I decided to do my first flashlight modification using a Luxeon Star. Since I had a stock LXHL-MW1C (no optics, hexagonal board), I figured I'd find a flashlight that would let me mount the light to a good heatsink.

This runs a stock Luxeon Star at 310-320mA, constant current, down to an input voltage of 0.92V.

Well, actually it runs at full brightness down to about 1.1V, and then at a much reduced brightness down to 0.9V or so. Alkalines, BTW, hate putting out this much current. I got a continuous run time at full brightness of a little over 2 hours (with a period at low brightness (moon mode?)). NiCd or NiMH batteries should do much better at this high current. I expect to get about 4 hours with 1600maH NiMH cells.

I found the Coleman double AA flashlight at Wal-Mart. It has a 0.25" thick brass plate that the bulb mounts in; this is just big enough to mount a stock Luxeon Star to. So I drilled and tapped a couple of 4-40 holes, and drilled a 1/8 inch hole to pass the wires (2 for the LS, 1 for ground).

Then I made one of my LT1308B constant-current booster circuits in a circular size. I made it on 0.010" thick PC board material.

I also made a disk of 0.010" circuit board material for the positive battery contact.

Then I used hot-melt glue to mount the battery contact board above the components of the booster, making a disk about 0.145" thick.

After trimming the reflector, mounting the LS and booster module, and wiring both together, I put in batteries and it worked!

These are comparisons between my light (on the right) and a Energizer Double Barrel 4-AAA flashlight.

One nice thing about this light is that you can use the original focus adjustment to get some beam shaping.

Many thanks to Ned K. for sharing this project with FlashlightReviews.com and its visitors!