PR Bulb Base LED Modification

 
 
 
Nichia LEDs
         

OK. This was my first ever mod. Get a PR Base flashlight bulb. Simply break out the glass with a pair of pliers. Wrap a napkin over the glass to prevent pieces from flying all over the place first, and hold over a trashcan. Then get a drill with a bit about the same size as the inner diameter of the base and drill out the epoxy inside. De-solder the bottom of the bulb so you have a hole. Cut the positive lead of the LED just above the little standoff tabs and attach a 1/4 Watt resistor. The tips and tricks page shows you how to calculate the proper resistance for the Voltage you have in the flashlight. Now bend the LED leads so the resistor lead goes through the hole and the negative LED lead is bent up and over the edge and rests on the edge of the base. Trim and solder. That's it! Fill with glue if you like.
Use the same technique for the 3 led's. You need a resistor attached to each LED. Be careful the positive and negative leads don't accidentally touch. Coat the positive leads with clear fingernail polish or liquid electral tape. These leds are available from whiteleds.net.
Here is a shot from the end - you can see that I used a spiral arrangement for the leads. Pre-tinning the top lip of the bulb base REALLY helps the solder connections!
An Energizer ArcWhite - Was on clearance at WalMart for 9.50. Still 16.00 at Lowes.
And here is the reflector end with the mod. installed. I had to file the outer edges of the 3 LEDs in order to make it fit, but filing the SIDES has no effect on light output. Just don't mar the TOP!

 

 
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