Flashlight Mod?

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HippyGirl

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Oct 30, 2009
407
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Thanks!

I didn't think to check the voltage under load before I epoxied the cap on (and there's NO WAY I'm taking it back off!), so I'm not sure if it's putting out the power it should, but it seems to be. BIG vapor anyway!

Now, if someone would be so kind as to tell me what size drill bit I need to make that damned hole for the 801 IN ONE PASS???

The cap is a fender washer...I worked on that hole with my flexshaft and a grinding stone for almost an HOUR before I got it juuuuuuuuust the right size so I could press-fit the connector tightly into it. And that was AFTER I had already ground the overall diameter down so it would juuuuuuuust fit into the opening of the FL. Which begs another question:

Is there something better than a fender washer to use for the cap?

Thanks!

Sherry
 

WillyB

Vaping Master
ECF Veteran
Oct 21, 2009
3,709
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USA
Thanks!

I didn't think to check the voltage under load before I epoxied the cap on (and there's NO WAY I'm taking it back off!), so I'm not sure if it's putting out the power it should, but it seems to be. BIG vapor anyway!

Now, if someone would be so kind as to tell me what size drill bit I need to make that damned hole for the 801 IN ONE PASS???

The cap is a fender washer...I worked on that hole with my flexshaft and a grinding stone for almost an HOUR before I got it juuuuuuuuust the right size so I could press-fit the connector tightly into it. And that was AFTER I had already ground the overall diameter down so it would juuuuuuuust fit into the opening of the FL. Which begs another question:

Is there something better than a fender washer to use for the cap?

Thanks!
You should find one of these, mine came with my drill.

41thgvNPXxL._SL500_AA280_.jpg


Is your washer just to hold the connector or is it providing the only ground?
 

Nietzsc

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Sep 27, 2009
279
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México
View attachment 5760

It ain't purdy, but it works...and it's a fog MACHINE! Actually made me cough!

As you can see, I made it for an 801 atty, but I ordered the 801>510 and 801>901 adapters from Heaven's Gifts (along with a couple of 901 attys so I can try the 901s).

Ironically, this is the first mod I've made that worked on the first try!

Me so happy! :D

Worked 3rd shift last night...now I'm going to bed.

Sherry

haha, alright hippy, you got it!!!
 

bigozone

Senior Member
ECF Veteran
Sep 6, 2009
237
0
Kentucky
Thanks!

I didn't think to check the voltage under load before I epoxied the cap on (and there's NO WAY I'm taking it back off!), so I'm not sure if it's putting out the power it should, but it seems to be. BIG vapor anyway!

Now, if someone would be so kind as to tell me what size drill bit I need to make that damned hole for the 801 IN ONE PASS???

The cap is a fender washer...I worked on that hole with my flexshaft and a grinding stone for almost an HOUR before I got it juuuuuuuuust the right size so I could press-fit the connector tightly into it. And that was AFTER I had already ground the overall diameter down so it would juuuuuuuust fit into the opening of the FL. Which begs another question:

Is there something better than a fender washer to use for the cap?

Thanks!

Sherry

did i forget to say that a quarter fits in most magnums pretty good...8-o

i found a way to make the washers the correct outside diameter easier... put 3 or 4 on a screwdriver shaft and run aginst grinding wheel... they spin and grind pretty uniformly...

and using a drill bit on a dremmel i can bore out a washer in 5 mins max...

i'd love to run across some of those mythical CISCO end caps for magnums....

i'll take 20 please....
 

jenntek

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Verified Member
Dec 15, 2009
76
6
Allegheny National Forest
I bought 2 of those caps/covers at Lowes... I drilled and drilled and drilled. I too realized it was a bit "undersized" I gave up on the drilling... I did, however get the pilot hole...
It was very late when I was working on my 2nd mod.
I will go at it this spring when my garage thaws out (Just kidding)
I don't care much for JB Weld, but, what else is there that is strong enuff?
 

HippyGirl

Super Member
ECF Veteran
Oct 30, 2009
407
4
Alabama
I bought 2 of those caps/covers at Lowes... I drilled and drilled and drilled. I too realized it was a bit "undersized" I gave up on the drilling... I did, however get the pilot hole...
It was very late when I was working on my 2nd mod.
I will go at it this spring when my garage thaws out (Just kidding)
I don't care much for JB Weld, but, what else is there that is strong enuff?

I ran into the same problem drilling that cap. I started TRYING to drill it out using my flexshaft, but managed to only make a good "dimple". When my DH got home from work, I got him to break out his big drill and finally managed to get it done. When I bought it, I THOUGHT it would be easy to drill, but nooooooooooo.

As for an adhesive other than JBW, I used "Locktite Quick Set Two Part Epoxy" in my first FL mod with equal success. The only thing about the Locktite is I don't like the dispenser...too hard to get the material flowing properly to me. With the JBW, I have two separate tubes and can simply squeeze out a dollop of each and mix.
 

Wireguy

Super Member
ECF Veteran
Oct 24, 2009
932
1
Birmingham Al
Hello night owls!

You can also put a bolt with a nut to tighten through them, chuck (no not the mod) them into a drill(press), hold a coarse file against them until it fits. If you need a finer finish stop when it is so close it almost fits and use finer and then finer grit sandpaper until ypu get the finish you want.


i found a way to make the washers the correct outside diameter easier... put 3 or 4 on a screwdriver shaft and run aginst grinding wheel... they spin and grind pretty uniformly...
 

Nietzsc

Senior Member
ECF Veteran
Sep 27, 2009
279
9
México
The one that I got doesn't have anything for the pcb to rest on within the light bulb portion, it sits over the main body of the flashlight. Instead originally the pcb rests on a metal ring right where the thread of the light bulb starts. :confused:

So, until I receive my cr2's to make the proper measurements, I'll hang on to my mini mag (which vapes pretty well)
 
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