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Old 12-28-2011, 02:24 AM #1
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Default Attaching wire to body of a flashlight

Im trying to get rid of the spring setup a host currently uses.
To do this I need to attach a wire to the body of the host (On the inside, but still accessible)
The hosts build material is listed as aluminimum aloy.

How would you recomend I go about doing this?

Drill a hole and tap it, then attatech the wire under a screw? (Never done this, dont own tools to tap a hole)
Use aluminum solder? (Dont have alu solder, my soldering iron is a 40w Weller, will it be enough)
Somthing that I am not thinking of?



Last edited by justinjja; 12-28-2011 at 02:25 AM.
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Old 12-28-2011, 04:10 AM #2
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Default Re: Attaching wire to body of a flashlight

In order to give you any bit of advice, a link to the host you have, or a picture would be required. Also, how you want to turn it on (existing switch or external switch, etc.)

If you are going to be bypassing the batteries that go in it, you could use an external switch and run wire through the tailcap. Just an idea since I have no idea what your host looks like.
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Last edited by Lotus_Darkrose; 12-28-2011 at 04:12 AM.
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Old 12-28-2011, 04:14 AM #3
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Default Re: Attaching wire to body of a flashlight

Quote:
Originally Posted by justinjja View Post
Im trying to get rid of the spring setup a host currently uses.
Why ?
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Old 12-28-2011, 04:17 AM #4
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Default Re: Attaching wire to body of a flashlight

Quote:
Originally Posted by justinjja View Post
Im trying to get rid of the spring setup a host currently uses.
To do this I need to attach a wire to the body of the host (On the inside, but still accessible)
The hosts build material is listed as aluminimum aloy.

How would you recomend I go about doing this?

Drill a hole and tap it, then attatech the wire under a screw? (Never done this, dont own tools to tap a hole)
Use aluminum solder? (Dont have alu solder, my soldering iron is a 40w Weller, will it be enough)
Somthing that I am not thinking of?
More info needed...

What spring set up? You mean the tail cap spring?
Is it for a laser build?

With more details, and/or pictures as mentioned, people will be able to give you some advice on how you can make it work...
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(just a few - too many to list) RPL 425, Sypder III Krypton, RPL 35 (473), GLP-473, GLP-593.5, HeNe 632.8,
Many DIY 445, red, blu-ray, green, 635, and 450 builds...


Looking for a DIY kit?


Take a look at some of my more popular kits linked in color...

* FS: 405-G-1 Glass Lens Mod for Blu-ray! 31% increase in power vs AixiZ acrylic!

* FS: New! 1000 Lumen XML-2 Maglite Modification With Voltage Monitor! - Parts or Complete Light! Must see!

* FS: Polished Stainless Steel Green Kit! Easy assembly in minutes!

* FS: Large Maglite Monster Kits! Side Button Forward Clicky! Custom Head Option! Gnarly...


Click here for a list of my build kits! Projects and tutorials too!

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Old 12-28-2011, 04:20 AM #5
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Default Re: Attaching wire to body of a flashlight

I'm going out on a limb assuming he means the spring on the driver, but that's going on almost zero information provided.

Either that or he wants to make it a side clicky, who knows.
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<+vk2fro> mines to operate off two SLA batteries
<+GBD> SLAs? whimp
<+GBD> get a 240V variac and some multiplier :P
<+GBD> then you can have some *real* fun
<+vk2fro> on camping trips where do you expect me to plug that in? a gum tree?

Last edited by Lotus_Darkrose; 12-28-2011 at 04:20 AM.
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Old 12-28-2011, 04:25 AM #6
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Default Re: Attaching wire to body of a flashlight

1mm thick aluminum sheet metal. Cut a strip slightly shorter than the internal diameter of the host. Fold a 3 to 4 mm portion of the end over. Crimp it onto the exposed end of a wire. Use lots of strength so that the wire can't pull loose. Curl the strip of aluminum into a circle, and then position it inside the host such that its own tension holds it firmly in place.

This approach presumes that the inside of your host isn't anodized.
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Last edited by rhd; 12-28-2011 at 04:26 AM.
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Old 12-28-2011, 04:30 AM #7
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Default Re: Attaching wire to body of a flashlight

Sorry, meant to post a pic...
Im moding a flash light to be a laser host, the original LED assambly had springs on it,
Here is a pic:


I guess I could come up with a way to attach the old spring to my laser heatsink.

EDIT: to give you a little perspective, the battery is an 18650

Last edited by justinjja; 12-28-2011 at 04:33 AM.
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Old 12-28-2011, 04:31 AM #8
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Default Re: Attaching wire to body of a flashlight

If it's a negative wire at the pill (very normal situation), then one method, is to pinch a wire between the edge of the contact board and the pill where the board is pressed into the pill.

Normally, the pill will have bare metal threads, contacting bare metal threads of the host... (path to battery)
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Many DIY 445, red, blu-ray, green, 635, and 450 builds...


Looking for a DIY kit?


Take a look at some of my more popular kits linked in color...

* FS: 405-G-1 Glass Lens Mod for Blu-ray! 31% increase in power vs AixiZ acrylic!

* FS: New! 1000 Lumen XML-2 Maglite Modification With Voltage Monitor! - Parts or Complete Light! Must see!

* FS: Polished Stainless Steel Green Kit! Easy assembly in minutes!

* FS: Large Maglite Monster Kits! Side Button Forward Clicky! Custom Head Option! Gnarly...


Click here for a list of my build kits! Projects and tutorials too!

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