It seems daft to post another thread with a similar title, so I thought I might jack this one. I'm working on my first mod using a Garrity brand flashlight. I'm pretty sure it's steel. It has a button on the end, none on the side. It took 2 AA's, but I've cut it down (using a tubing cutter, nice and smooth) from the light end so I can still use the end button as a master on/off. I'm using a 14500 battery and a 510 connector. It should turn out pretty nice-looking when it's all done. The problem is that I want a momentary pushbutton on the side, near the atty connector. I've left plenty of space, but the problem is drilling a hole in the side of the tube. It's a little thicker than I expected and I'm not sure what I should be using to do the deed. I would say it's about the thickness of a penny.
I'm using an 18v drill, but I think I need new bits for this. Is there a specific kind I should be using for drilling into steel? Also, is there any trick for getting the drill to go into the tube without kicking all over the place? Finally, are there any tips for a "spacer" to stick inside the tube to hold the battery in place, against the negative spring? Funds are very limited, but I can manage a few bucks for some sort of epoxy or somesuch if that's the recommendation.
I should mention, the tube itself is the negative and I have a washer which perfectly fits on the open end that the 510 connector fits into. Is there a clever way to connect that washer other than pure solder that would look nice and still complete the circuit? Oh, the flashlight is this one: