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Old 12-21-2010, 07:54 AM   #1
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Cool Easy Maglite P7 Mod! Nice...

Also, check out my new 1000 Lumen XM-L T6 Maglite Modification kit! Awesome!

http://laserpointerforums.com/f64/fs-1000-lumen-xm-l-t6-maglite-modification-kit-parts-complete-flashlight-59581.html








I bought a drop in reflector/heatsink/driver/P7 module from DX and fit it into a 2D Maglite...



I'm using 2 X 5000mAh 32600 Li-Ion batteries for this bad boy.

Here's the P7 module:
DealExtreme: $22.28 SSC P7-C 2800mA LED Module with Copper Base (3.6V~8.4V)

Here's the batteries:
http://www.kaidomain.com/ProductDeta...ProductID=2708

Here's the charger you want for these large batteries:
Ultrafire WF-188 Charger for 14500 / 17500 / 18500 / 18650 / RCR123 3.7 volt Lithium Battery Charger




Details of this easy modification are shown in this 'picture tutorial'...




Switch removal and modification:

The switch needs to be removed. Then cut the center post that holds the stock bulb short.

Then solder on lead wires as shown in the pictures.










Fitting the reflector:

The reflector fits, but it sits a little higher than the stock reflector, so it would leave a gap between the retaining ring/bezel of the host, and the head unless some modification is done...





Machining the head down, also adds to the heatsinking. Because the thick aluminum reflector now gets pressed tight onto a bare metal edge of the head!







Battery prep:








Tail cap mod:

I modified the tail cap spring just because I wanted it to fit the 32600 Li-Ion batteries better. The stock spring position was a little too tight. The tail cap can be further modified if you wanted to fit 6000mAh 32650's...








Adding some extra heatsinking for the P7:

Since I like very much the way this easy build came out, and I think I got a nice P7 module, I went ahead and added some extra heatsinking for it!




Might as well make this bad boy a little more comfortable in it's new home!






Final assembly:

That's pretty much it! Then just put it together...









Current Draw: (measured at the tail)

* 1360mA's - Estimated run time between charges: 3 1/2 hours...

This P7 gives a little better throw than my two other P7 flashlights, with less battery current draw! (1360mA's)

Also, it is slightly brighter than my 2 X 18650 P7 build which is drawing 2.6 Amps.

This has me scratching my head...

This mod is probably taking about 2.6 Amps to the emitter. But I just don't understand why my other P7, with 2 X 18650's is measuring 2.6 Amps at the tail?? Maybe my other one has a linear driver or something...

Oh well...

Hope you like this build! I know I do...





Beam shot:

The face of the cave on my pool where the steps are, is 60' away, and the very back corner at the fence is 85'...





Take a look at my XM-L T6 Maglite 'Stubby' (cut down to fit a single 32600) here!
http://laserpointerforums.com/f64/fs...ght-59581.html
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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...


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Last edited by jayrob; 05-29-2011 at 06:07 AM.
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Old 12-21-2010, 07:46 PM   #3
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Default Re: Easy Maglite P7 Mod! Nice...

Ha ha!

Yeah those are cool... err, rather 'Hot'!

I'm more for usfulness and longer run times for a flashlight...

I've got plans and parts ordered for my up coming Mag D 'Stubby' that will be using a single 32600 (or 32650).

It will have a 3 mode driver that will run the XM-L T6 emitter at up to 1000 lumens. (or hopefully near that)

It should be maybe 2 or 3 hours run time on high. But on low, it would have a really long life with that battery! And still be plenty bright!

I'm going to make a custom mount for the Maglite D 'Stubby' shown here: (my Q5 prototype will go over 4 1/2 hours on high, and over 30 hours on low!)
http://laserpointerforums.com/f66/fs...0-a-59018.html

The custom mount will be similar to this: (except it will have a post to mount the emitter on, and a driver cavity. All in a one piece unit)

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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...


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Last edited by jayrob; 12-21-2010 at 07:57 PM.
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Old 12-22-2010, 09:50 AM   #4
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Default Re: Easy Maglite P7 Mod! Nice...

Sweet. That thing lights up your Living area Like sunlight.

Well it could be a different Bined P7 witch is brighter so yea thats always a good thing.

Nice chunky heatsink I bet the light doesn't even get hot.

As always.
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Old 12-22-2010, 09:58 AM   #5
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Default Re: Easy Maglite P7 Mod! Nice...

It's most likely an older bin, the older P7s had cloudy domes. It's still a powerful light nonetheless.
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Old 12-22-2010, 02:42 PM   #6
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Default Re: Easy Maglite P7 Mod! Nice...

You probably already know this, but did you double the current draw that you read? With twice the voltage you only need half the amps. If you did the brightness confuses me too. This looks nice. Can't wait for that XM-L to be done! I'm also ordering my first soon.

Proto, I noticed the cloudy dome too. Though it isn't a bad thing, the only thing I can tell that's different about it is you get more flood and less throw. What really surprises me is how far this one throws! The cloudy P7 I have is basically a floodlight.

EDIT: About that reflector, could you just use a large o-ring and not machine anything? For us poor folk who don't have lathes...
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Old 12-22-2010, 03:22 PM   #7
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Default Re: Easy Maglite P7 Mod! Nice...

Quote:
Originally Posted by Prototype View Post
It's most likely an older bin, the older P7s had cloudy domes. It's still a powerful light nonetheless.
Cloudy dome? Do you mean the lens over the emitter? If so, it's just the angle of the camera or something...

I held the flashlight under my desk light, so maybe there was a reflection or something. Here's a clear picture of the emitter:

I updated the first post with a better picture...






Quote:
Originally Posted by randomlugia View Post
You probably already know this, but did you double the current draw that you read? With twice the voltage you only need half the amps. If you did the brightness confuses me too. This looks nice. Can't wait for that XM-L to be done! I'm also ordering my first soon.

Proto, I noticed the cloudy dome too. Though it isn't a bad thing, the only thing I can tell that's different about it is you get more flood and less throw. What really surprises me is how far this one throws! The cloudy P7 I have is basically a floodlight.

EDIT: About that reflector, could you just use a large o-ring and not machine anything? For us poor folk who don't have lathes...

I'm very excited about the XM-L T6 emitter too! Thanks for telling me about it!

Edit: Here's the XM-L T6 build:
http://laserpointerforums.com/f64/fs...ght-59581.html

I got e-mails this morning that the emitters have shipped. Same for the drivers!

I'm going to make a custom heatsink/mount for the emitter. That will have a driver cavity, and be able to mount into the Maglite barrel similar to my Q5 mod shown at the bottom of the first post in this thread. But it will be a one piece design. I think it will be awesome...

I can't believe the efficiency that I have been reading about! A Q5 will give about 220 lumens at 1 Amp. But the XM-L T6 is supposed to give 386 lumens at 1 Amp with a forward voltage of less than 3 volts...

That's 75% more output with the same current!!!

I'm going to be testing two different configurations using the large capacity 32600 Li-Ion batteries:

* A single 32600 (or 32650) build using this driver: (Maglite D 'Stubby)
http://www.kaidomain.com/ProductDeta...ProductId=1845

* And a 2 X 32600 build using this driver: (Maglite 2D)
http://www.kaidomain.com/ProductDeta...ProductId=1866

I'll make known the results in my up coming thread about these flashlight mods!

About the P7 mod... If you don't machine the head down on the P7 mod, then you will have about a 2.5mm gap between the bezel ring and the head. It won't screw down all the way... (but it will still screw on, and hold the P7 module in place)

So if you want it to screw on all the way, and look nice, the lip on the head must be shortened. I can do it on the lathe in just a few minutes. I can grip the head from the inside. So as not to scratch the finish... (but I would think it's best to have the new reflector/P7 module on hand - to get the fit just right)

Please tell me more on what you mentioned about 'twice the voltage, 1/2 the Amps'...

I'm not following this??

Only because I have a different P7 build that uses the same voltage. And I get 2.6 Amps current draw measured at the batteries.

So obviously it will depend on the driver. I'm thinking that the other one must have a linear driver...

I'm still loosing only 1360mA's from my batteries at full charge. (I did not double the reading. I'm taking my measurement between the batteries and the host)

In fact, I tried to test with a single Li-Ion on this P7 module from DX, and it would not light. Only with 2 X Li-Ion's...
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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!


Last edited by jayrob; 01-23-2011 at 07:36 PM.
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Old 12-22-2010, 08:26 PM   #8
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Default Re: Easy Maglite P7 Mod! Nice...

But it still functions normally with the 2.5mm gap?

Technology has come so far since the Q5! Actually I think the R5 is more efficient at lower powers, so it's better for an EDC. When I say low I mean like <150 lumens. But are you sure that driving an XM-L at 3 amps is a good idea? I actually have no idea, but I haven't seen one driven that hard yet, and I know that the ideal current is either 2.6 or 2.8 (can't remember). How much did you pay for the emmiters?

LEDs work in terms of electrical power, current x voltage. So basically a P7 driven at 3A with 4.2V will have the same output as one driven at 1.5A with 8.4V. If it was driven at 3A with that much voltage, it would be the equivalent of a single cell @ 6A, and would probably blow or burn out quickly.

I've got both threads subscribed!
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Last edited by randomlugia; 12-22-2010 at 08:29 PM.
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Old 12-22-2010, 08:59 PM   #9
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Default Re: Easy Maglite P7 Mod! Nice...

Yes, still works without modification, but has a gap is all. (cosmetic)

I bought the XM-L T6 emitters here because I need them on a 14mm round board to fit through the Maglite reflector for focusing:
Cutter Electronics

They are about $10 bucks each. Let me know if you have a better source...

Check this data sheet: (it says they can be driven at 3 Amps)
http://www.cree.com/products/pdf/XLampXM-L.pdf

But I'm guessing the driver won't really put out 3 Amps anyway... So it should be perfect!
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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...


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Last edited by jayrob; 12-22-2010 at 09:38 PM.
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Old 12-22-2010, 09:11 PM   #10
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Default Re: Easy Maglite P7 Mod! Nice...

Quote:
Originally Posted by randomlugia View Post
But are you sure that driving an XM-L at 3 amps is a good idea? I actually have no idea, but I haven't seen one driven that hard yet, and I know that the ideal current is either 2.6 or 2.8 (can't remember). How much did you pay for the emmiters?
These things are tough, this guy here took one to ~5.7A and it didn't even go that angry blue!
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Old 12-22-2010, 10:22 PM   #11
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Default Re: Easy Maglite P7 Mod! Nice...

5.7A, direct drive?! Man those things are hungry.
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Old 12-23-2010, 01:09 AM   #12
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Default Re: Easy Maglite P7 Mod! Nice...

That guy is Techjunkie lol. Nice mod!
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Old 12-23-2010, 01:42 AM   #13
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Default Re: Easy Maglite P7 Mod! Nice...

I'm pretty sure it's not the same person.
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Old 12-23-2010, 02:28 AM   #14
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Default Re: Easy Maglite P7 Mod! Nice...

Hey I just got my Malkoff Drop-In Module for 3-6 D-Cell to fit Mag-Lite...It's not bad! It drops right into a Maglite barrel. See here:
Drop-In Module for 3-6 D-Cell to fit Mag-Lite [3-6 D-Cell Drop-In] - $69.00 : Malkoff Devices. Super bright, powerful LED modifications for flashlights, Super bright, powerful LED modifications for flashlights

I only tested it to do a comparison with my other lights and it has a steady current draw of 700mA's from a single Li-Ion battery. Looks like it's fairly brighter than a Q5 visually. But at only 700mA's instead of 1 Amp... (from a single Li-Ion)

It's just a single mode.

Personally, I'm favoring my Q5 set up because it has 3 modes...

But it's a nice set up. And the center spot is better than the Q5.

It cost me $69 dollars plus $8 dollars shipping...

If anybody wants to buy it from me, I'll let it go for $55 dollars plus $4 dollars shipping.

Just send me a PM if you want it!


Edit: SOLD
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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!


Last edited by jayrob; 01-23-2011 at 07:39 PM.
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Old 12-23-2010, 06:07 AM   #15
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Default Re: Easy Maglite P7 Mod! Nice...

I think you should hold on to it... That's a really nice piece of equipment there. Just look a little bit deeper, build quality, tint, beam pattern, regulation - there are a lot of things that set quality electronics apart from 'made in China' production line stuff, and a lot of reasons why some people refuse to buy the latter. Brightness isn't everything.
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Old 12-23-2010, 06:28 AM   #16
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Default Re: Easy Maglite P7 Mod! Nice...

By the way, I tested it with a single Li-Ion vs 2 X Li-Ion's because it is for 3 to 6 D Mag...

And it acted just like you said in a couple of posts above. Half the current draw with 2 batteries.

I just wonder why my 2 X 18650 P7 build is so strange in that it draws 2.6 Amps with 2 batteries?? It has to be a linear driver...

I mean there must be a driver in the Malkoff module right?
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Old 12-23-2010, 02:20 PM   #17
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Default Re: Easy Maglite P7 Mod! Nice...

Is that before or after dividing it? Because if you didn't that's a ton of current for the LED. If it hasn't popped yet and you've got good heatsinking, it probably isn't a problem though.

There is a driver in the Malkoff; they've got really nice current regulation.
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Old 12-23-2010, 03:26 PM   #18
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Default Re: Easy Maglite P7 Mod! Nice...

All of the measurements I've mentioned are direct readings from my meter. No division or anything...

I just put fresh charged batteries in my dual 18650 P7, and I get 2 Amps current draw at the batteries with UltraFire. It will draw 2.6 Amps with AW's.

Still, side by side with this Maglite P7 mod, the Maglite is a little brighter. But the current draw from the dual 32600's is only 1360 to 1390mA's. I tried it with the AW's and got the same reading... (no division)
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Old 12-23-2010, 07:03 PM   #19
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Default Re: Easy Maglite P7 Mod! Nice...

Then I really have no idea why it's brighter... Maybe one of our LED experts will chime in soon.
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Old 12-23-2010, 08:39 PM   #20
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Default Re: Easy Maglite P7 Mod! Nice...

Quote:
Originally Posted by randomlugia View Post
Then I really have no idea why it's brighter... Maybe one of our LED experts will chime in soon.
Well it's not super brighter. The other light is very comparable...

But side by side, I can see a little brighter flood area with the Maglite.

The big difference is in the amount of battery current draw. Unless I'm missing something, this tells me how long I can expect my batteries to last by calculating the battery current draw vs the capacity of the batteries...

So the one light will probably only last an hour or so. But the Maglite build should last maybe 3 1/2 hours.

If my thinking is flawed in this assumption, please advise! (I'm mostly into building lasers, but getting into Flashlights now)
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* 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!

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Old 12-23-2010, 09:54 PM   #21
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Default Re: Easy Maglite P7 Mod! Nice...

That thinking is a little bit flawed, not much. Getting back to my point about better flashlights, current regulation is everything. A light with good regulation will be at full brightness for the entire battery life and suddenly cut off. A light that's directly driven or has a cheaper driver will slowly slope down in brightness throughout the battery life. Doing so will extend the runtime, but obviously the light won't stay bright and you'll have to keep the batteries topped off to keep it bright. Another factor, you can't completely drain the battery, only to about 3.0-3.2 volts. Really the only way to test runtime is to actually test it.

It should last longer than an hour, my 3A driven P7 lasts an hour on an 18650. Those 32600 batteries have twice the capacity. 5000mAh, right?

Beamshots?
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Old 12-23-2010, 10:56 PM   #22
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Default Re: Easy Maglite P7 Mod! Nice...

I'll get a beam shot tonight when it gets dark...


I figured that since I have an 8.4 volt supply (full charge), and maybe 6 volts at time for charging, that the driver will not need to pull extra current for any boosting like we do with blu-ray diodes and boost drives for a single Li-Ion build...

So I'm thinking that my run time will be maybe 3 1/2 hours before charging will be needed. But yeah, I realize that the only way to know for sure, is to test it...

How much forward voltage does a P7 emitter take?






Update - Adding some extra heatsinking for the P7:

Since I like very much the way this easy build came out, and I think I got a nice P7 module, I went ahead and added some extra heatsinking for it!




Might as well make this bad boy a little more comfortable in it's new home! (adding this to the first post)
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* 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!


Last edited by jayrob; 12-24-2010 at 07:07 AM.
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Old 12-24-2010, 12:27 AM   #23
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Default Re: Easy Maglite P7 Mod! Nice...

I'm not sure about the forward voltage of a P7, it varies between emitters. The best I can tell you is that it will usually pull between 1.8 and 4.5 amps at 4.2V, from reading reviews and personal experience.
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Old 12-24-2010, 05:20 AM   #24
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Default Re: Easy Maglite P7 Mod! Nice...

Ok cool... I knew it had to be less than 6 volts...

Which means that my current draw from the batteries won't go up as the voltage drops...

Here's a beam shot that I'm going to also add to the first post...

The face of the cave on my pool where the steps are, is 60' away, and the very back corner at the fence is 85'...

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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!


Last edited by jayrob; 12-24-2010 at 05:29 AM.
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Old 12-24-2010, 06:36 AM   #25
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Default Re: Easy Maglite P7 Mod! Nice...

That's looking really cool!

Quote:
Originally Posted by jayrob View Post
Which means that my current draw from the batteries won't go up as the voltage drops...
Yeah, that's what the drivers are for.
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