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The trick to this mod is in the LED preparation.
First, since there will be no reflector, be sure to choose
LEDs that have a tight focus. Also, if the LED's have a shoulder
at the base, you have to first file that shoulder down completely
flat. The LEDs must be able to fit together side-by-side,
and still have a parallel aim (not "nose in"). Also,
you still have to file the solder tabs off. Once that is out
of the way, trim the + lead on one LED to about the same length
as the original bi-pin bulb, and trim the - lead on the other
LED to that same length also. Keep in mind that these two
will need to be situated close together so they can fit into
the bi-pin socket. Then you have to join and trim the two
remaining leads. Make the join as small as possible to avoid
grounding problems when the head is assembled.
Once you've mounted the joined LEDs in the Solitaire,
you can make final adjustments to get them perfectly aimed
just by bending the leads around a bit while running the light
to see the beam pattern. Once the aim is perfect, place a
*SMALL* drop of superglue where the LED's are resting together,
touching. Let the assembly dry for at least an hour before
handling it again.
Also, you have to remove the reflector from
the head. The reflector and lens can be driven out usually
w/o damage by using a small socket (3/8" or so) and a
hammer. Just set the lens on the socket, and give the back
of the head assembly a couple of light taps with a hammer.
Also, I like to put a stop on the flashlight
body to keep the head from screwing too far down, where it
might possibly bend and stress the LED leads too much. I superglued
on a thin piece of curved plastic trimmed from a cheap ink-pen
cap. See the black rectangular piece of plastic near the O-ring
in this photo:
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