This is another great mod sent in by Ying Chee L. of Melbourne, Australia.

Seeing as I had the idea earlier on, and finally went and purchased a DB 4AAA yesterday. I was rewiring the DB to 6v Please refer to Quickbeam's page on how to.

If you've successfully rewired the light to operate at 6v, then you'd already know that there's a white housing that contains the bulb and the switch.

However, some points that I'd like to point out is that the end cap of the DB (where the negative side goes) has a circular shaped contact with a hole in the middle. This means that if you put the positive contact of a AAA cell to it, the nipple will just go in the middle and no contact can be made. As many people has pointed out, you can use a bit of aluminum foil to provide contact but I put solder on the contact covering the hole in the middle. You can see this in the following photo.

For the bezel side of the DB, the contacts are designed for positive contacts of AAA cells, being the nipples. The photo above shows the bezel (with reflector forcefully removed), the end cap with one side soldered, and two springs. These two springs are the positive contacts for the DB. There is a little black plastic cap that is on the end of the spring which fits over a nipple of an AAA cell, this and the end cap provides some polarity protection. I trimmed the black plastic piece all the way around until contact could be achieved when pushing it against the negative end of an AAA cell.

First I took the P61, and removed the two springs with a soldering iron. Then I placed it in the bezel and attempted to screw it in. Nope, too tall, it's pushing against the white bit where the stock bulb goes in. So we have to carve a hole for it to go deeper. I don't have access to any powertools at all, so I "carved" out the hole with soldering iron, melting the plastic and fitting the P61 at the same time to see if it fits. After getting a big enough hole, I put the P61 in the hole and screwed the bezel back on. It works, however there is a small approx 2.5mm gap between the bezel and the light. Anyway, it screws on, who cares about a gap anyway. On to the next step.

Take your favorite knife, this can be anything from a paper cutter, to fancy folders, to a meat cleaver. And use it to cut and wedge the white switch/bulb assembly apart. Leave the switch alone, and solder wires to the original bulb connector to the P61 contacts. Try to make the length of the wire just right, because it will be a tight fit. Put it back together, and it should look like the above photo. Shove the whole thing back into the DB, note that you can't screw the two screws on the white bit back in because the reflector is in the way. But this doesn't matter since the lens will push on the reflector which will in turn hold the white bit in place anyway. Screw the bezel back on, and vola, light.