4300 lumen 2D mag-lite

thingiverse

Human: 4300 lumen Maglite equipped with a Cree XHP 70.2 LED and an Adventure Sport driver. To purchase the driver in a 6-volt form, visit https://asflashlights.com/-diy-parts/75-10-amp-capable-17mm-led-driver.html#/69-optional_parts-none/68-voltage-6_volt. For the heatsink, go to https://asflashlights.com/-diy-parts/32-heat-sink-for-maglite-d-cell-10mm-mcpcb.html. To acquire a replacement tail spring, visit https://asflashlights.com/led-upgrades-for-maglite/62-shorty-tail-spring-for-d-cell-maglite.html. A new lens is required as the plastic one may melt; you can find it at https://asflashlights.com/led-upgrades-for-maglite/120-ar-coated-lens-for-mini-maglite.html. The heatsink is designed for a 10mm MCPCB, but the XHP 70 is larger. Two options are available: grind down the center ring to make it flat or use a 10mm XHP50 LED, which still performs well. Additionally, a stud needs to be soldered to the driver to connect with the Maglite's positive contact and the on/off switch of the Maglite must be removed, along with cutting the end down to where the retaining bolt slides for the positive and negative contacts of the LED. The reflector requires being cut flush with the smaller hole at the back. I used a 2D Maglite that was already equipped with an LED from the factory. To complete this project, you will need to download a 26650 or 18650 adapter for a Maglite, available here on Thingiverse: https://www.thingiverse.com/thing:3817794. My own design for a 26650 can be found at the same location. The threads may be tight; unfortunately, there is no way in Fusion 360 to adjust thread sizes other than what is already in the software. I had to print mine at 100.3% scale for a better fit and it's essential to be cautious when threading this on for the first time to avoid crossing threads. Removing the O-ring will allow you to thread it fairly tightly – tight enough that it won't come loose. I have no affiliation with asflashlights.com. Update: I replaced the stud with a spring from https://asflashlights.com/springs/129-silver-plated-copper-core-spring-for-maglite-switch-tower.html, trimmed to about 5/8 in. It maintains a much better connection with the battery now.