Energizer DoubleBarrel 6 Volt 5 LED Mod

 
 
 
Nichia LEDs
         

I recently purchased one of the Inova X5's and just had to make that 6 volt DB 4AAA Mod a (5) LED lamp! The Inova is very impressive and I was able to pick up (5) brand new white LED's from Tanners so all would be the same lot.

I layed a quarter on a piece of perfboard and outlined it on the material. Then cut out circle with small pair of dikes. I found what was to be my two center holes and proceeded to lay out the 5 LED's so all would have one leg coming through one of the center holes. Soldered them all together and detached all but one leg to use as one of the lamp contact pins. On the back of the perfboard I ran a ring of wire around the outside LED legs and soldered all to this wire. I just used one of the cutoff legs to solder to the ring wire and it went through the other center hole. Fun part was getting these 2 legs in those tiny lamp contact holes when you can't see what you are doing. The perfboard now blocks your view! Hold your mouth just right and lift your left leg off the floor and you'll eventually poke it in the right place. I tried running at a straight 6 volts but with new batteries one of the LED's started to turn slightly blue and I know what that means. Quickly turned it off and took out a new battery and subbed one that wasn't totally new . All LED's did fine then. I am going to go back and add a 5 ohm resistor to one of the legs to limit current so I can use all new batteries at once. I was attempting to recreate the Inova X5 brightness with the DB and I have surpassed it! Witha 5 ohm resistor they should be about equal brightness.

I am attaching several images I shot with computer cam to show the mod. The reflector was drilled open by lowering pilot bit in a 1" hole saw so the pilot bit would not contact front clear lens. Slow drill and out came cone shaped piece of plastic. This leaves a little bit of the reflector inside the head to add to the output. Of course using all 4 batteries now. Soooo, for about $25 bucks total a person can imitate the Inova X5 with a modified DB 4 AAA. I left the lamp running last night as I slept. LED's were fine and after 4.5 hrs. I decided to just go ahead and turn it off. It was still as bright as the InovaX5 at this time and if I only get 5 hours from a set of batteries I am doing just fine in my book. May go to 10 or so total from a set!

Many thanks William I. for sharing this mod with FlashlightReviews.com!

 

 
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