I found that at work we had a 5/16" flange nut, that fit PERFECTLY in the end for the battery connector. The first one I grabbed and brought home, grabbed the drill and the biggest bit I had, wasn't nearly big enough so I figured I could just ream it to get it the right size, so I did that pretty much until the battery died. Went to see where I was on the hole to the battery connector and I needed the hole to still be much bigger. So when the battery charged I grabbed my chainsaw file and put it in the drill and tried that, still not big enough. I did this process a couple more times and just barely got it to fit by putting a dead atty on the connector and smashing it on with a hammer, looked horrible this way, all chewed up and beat up, but it worked. Today I redid it with a new nut and a new connector and a proper drill bit that work also had, along with a vice which I also don't have.
I drilled the hole for the switch, had to make it surprisingly almost as big as the lock washer the switch came with to allow me room to get in that small space. It's looking put together pretty well know, you'd never know of the issues I went through.
So here you have it
Using TrustFire16340 (is there a different battery that you could use in this to? or is this it?)
510 atty
SPST momentary Submini Pushbutton Switch from the local radio shack
Left the switch that was on it and use it as the main on off switch
Tools I have at home
A pair of dikes (thats what we call 'em at work, cutters, or whatever)
Needle Nose Pliers
Drill and bits that are not correct sizes
Wood burner I use as a soldering gun
Lead free solder that I got from work
It was a fun project and so far, well worth it. Don't know how many mods I will make with my lack of funds and tools. This might be all I need. Great mod and would have been easy instructions if I wasn't so damn impatient.
Thanks!