This tutorial is intended for US citizens that are only able to import 5mW or weaker lasers without FDA safety features.

This is legal because it is only illegal to import a handheld laser over 5mW into the US, you can import laser modules over 5mW without FDA safety features 100% legally. It is also legal to assemble your own handheld laser over 5mW as long as you don't sell it.

This mod requires very basic soldering skills.

Be careful with any laser, don't point it at aircraft and use goggles when necessary!

Step-by-step video:

Parts
For parts you will need:
-Any NewWish pen green laser. Here is the $10 "True 5mW" from DX
-A green laser module from this site. Here is the 200mW rated module (should output at least 100mW-150mW)
-A vise
-A soldering Iron
-A small 2x4 or similar block of wood.



Step 1 - Pointer Disassembly
Start by drilling a 1/2" hole in the block of wood. Next cut it in half so that you have a clamp that will hold your laser. The wood is used here so the metal vise doesn't scratch up the laser.


Place the silver cap into the clamp, and then tighten the vise. Wiggle the pointer around until the module pulls out, the module is only press fit in there so there is no glue or threads to worry about.



Step 2 - Module Mods
Take the button and set it aside, do not lose it! Take the foam spring protector and the silver cap off of the old module, and screw the silver cap onto the new module.


The new module will come with lead wires soldered to it, you will have to remove these by desoldering them.


Desolder the spring off of the old module and solder it on to the new module.



Step 3 - Reassembly
Put the button back into the laser pointer, and then align the module's switch with the button.


Put the module and pointer top in a vise and press them together, do NOT over tighten. Put a rag in the vice so you don't smash the pointer with metal on metal contact.


Put your batteries back in the laser and you are ready to go!

Depending on how powerful of a laser module you purchased, you could be able to light matches and pop balloons with your new laser.


Enjoy and be careful!

Very nice instructions, A++++

another one of your projects I am going to do.

Very nicely done!

Good job and nice instructions/pics +1

I love the last pic

Nice!

I had a feeling something like this could be possible with DX's high powered modules, i just didn't think it was going to be that simple

Good vid!


I was working recently on a upgrade for a DX purple pen.

I had removed the laser diode and replaced it with a PHR. But a bad solder connection broke and killed it (partly because I had to solder lead extensions and they where fragile). I'll try again when I'll have a new sled.

I really like your block + vice idea, thanks for sharing! I scratched the head of my laser while disassembling it, but I buffed and shined it up with my Dremel so now it's golden.

Thanks for the compliments guys!

BTW the block/vise trick isn't my original idea, I think it was Hemlock_Mike that first mentioned the idea a couple years ago. I've used it ever since without failure.

Guys, Where can I get some good quality and compatible modules for this pen? I like the pen style, but the module inside (with its optics) is so crappy.

Not so important as far as function, but I am curious how this affects battery life. I ordered a 30mW to do this with since 150mW seems like it may produce too much heat in this body.

Just have to take that into account and reduce the duty cycle.

O-Like is good for modules or odicforce.

jont, this thread was over a year old when you replied to it. What the hell were you doing? Fishing around 5-pages back?

Funny story...I got a 5mW laser and well...it just couldn't sate my lust for a powerful green laser. Styro's tutorial came up in a Google search for "Upgrade green laser", and I just figured I would put some life back into this thread. lol. I'm new to lasers, but they have always fascinated me, so I think it's time I start my journey into the world of high powered lasers.

Well next time start a new thread and just provide a link back to the old thread.

Will do. Most forums I belong to prefer the continuity. I don't have a preference. Thanks for the info.

This is by far this best laser upgrade I've seen so far, most of them just beat up on a poor 5mw diode. This is a great idea to just switch out the whole diode! Now my problem is that when I take the cap off the inside parts wont come out, it's like they are glued in and the cap is just pressed in there. Any ideas?

^Necro

Next time start a thread and link back to this.

I have no clue what Nerco means. Would you give me the defintion?

When someone says you necro'd post it means you took a thread that had been inactive for a while and posted in it. It doesn't sit too well with many members. It's best to start a new thread and link back to this one.

Just my own personal opinion but people who think negro posting is something bad can just sit on it !

I've never seen any one with any intelligence complain about it.

Of course there is that 1% of threads that contribute nothing to lasers that should have been erased anyway.

Any information that is a matter of record here should be allowed to be looked at with out being scoffed at for doing so !

Why the hell are we keeping the information around if were not going to look at it

Think about it if you can't have a good laugh over it and then get over it you probably need a drink

Remember there is always an exception to the rule

Chill...

Message received, understood, applied to life.

I'm glad this was bumped back up.

sorry jeff it just struck me funny...

Hey Jeff....

do you mean like if I posted "Is this still available... because
I really need one" on this thread it should be OK at anytime....

big chunk

It doesn't even state "SOLD" so I guess it's still active...




Jerry