4D Maglite Conversion

[4DMag-Lite]

Welp I finally decided to convert one of my old 4D icans to to LED.

For this I opted for the Malkoff M61W drop in. I wanted something in the middle of the road for use around the house, and at work, I wanted warm white and Hi-CRI something a little floody and a little spotty. I also installed a Weltool glass lens, and a bust a cap glass breaker.

I have another 4D incan that I plan on dropping in a M91T to have something more for the outdoors.

So far I'm pretty happy with the conversion, and the Malkoff drop in seems pretty stout.

 

[datiLED]

That light means business!

I have an old 4D Mag that a coworker found in a ditch. It is in rough condition, but would be a perfect host for an LED conversion.

 

[mrfixitman]

This is my modification using 24vdc bulb. 4 A123 26650's for 12.8vdc. Pitches a bright beam that lights up a wall 100 yards away. These cells can be had for as little as 50 cents each and can do 10,000 cycles and retain 50% capacity. However a dead short can quickly yield 200 amps for smoking and melting situations. Be careful. Flip and reduce spring in some cases and use a Dremel to take out the anodization in the cap for good contact.

 

[vicv]

This is my modification using 24vdc bulb. 4 A123 26650's for 12.8vdc. Pitches a bright beam that lights up a wall 100 yards away. These cells can be had for as little as 50 cents each and can do 10,000 cycles and retain 50% capacity. However a dead short can quickly yield 200 amps for smoking and melting situations. Be careful. Flip and reduce spring in some cases and use a Dremel to take out the anodization in the cap for good contact.

Why are you powering a 24vdc bulb with 12.8v? Surprised it even lights up

 

[mrfixitman]

Why are you powering a 24vdc bulb with 12.8v? Surprised it even lights up

4-24v bulb. Surprisingly works well at many voltages. Cheap, only a few bucks.

 

[vicv]

Oh so it's led? That's not a bulb. Was confused. That'll be a long running light

 

[bykfixer]

That Malkoff upgrade should do nicely.
Litt industries has a glass breaker tailcap with a cover so you can still tailstand the light.

Maglite Glass Breakers

- Machined from 6061 Billet Aluminum - Hardened Steel Tip - O-rings Pre-installed

littindustries.com

 

[xxo]

I have one of these in my old 4D Mag:

Maglite LED Conversion Kit for 2,3,4,5,6 D cell and C cell Maglights Flashlights

325 lumen instant upgrade with Luminus SST40 LED for super bright light and long range.

lumencraft.com

and run it on 2X 18650's. 21700's or 26650's like I use in my 4D ML300:

 

[mrfixitman]

This is my modification using 24vdc bulb. 4 A123 26650's for 12.8vdc. Pitches a bright beam that lights up a wall 100 yards away. These cells can be had for as little as 50 cents each and can do 10,000 cycles and retain 50% capacity. However a dead short can quickly yield 200 amps for smoking and melting situations. Be careful. Flip and reduce spring in some cases and use a Dremel to take out the anodization in the cap for good contact.

This modification including batteries, led, and PVC was 6 bucks.Had the light already. Can do the same with C cell MAG-LITE. Stretch or cut spring as needed. A new 3C MAG-LITE IS $20. Takes two 26650 for 6.4vdc. Stretch spring.

 

[alpg88]

In my experience 26xxx cells from pretty much every manufacturer would not fit in C Maglite. at least with post 1994 Maglite, we had to bore it out with hones so cells fit.

 

[alpg88]

D to 18650 adapter

 

[vicv]

D to 18650 adapter

I'll see your adapter adapters, and I'll raise you one I made on my mini lathe. Can't remember the grade of plastic. I think delrin. The brass pin is to give a bit of extra length, and to make it button top for the mag switch. Perfectly fits two 18650s in a 3C mag. You can hear the air escape as they slide down

 

[mrfixitman]

In my experience 26xxx cells from pretty much every manufacturer would not fit in C Maglite. at least with post 1994 Maglite, we had to bore it out with hones so cells fit.

I bought a used https://www.adorama.com/us1634597.html total of 20 bucks. Two 26650's by A123, the 50 cent variety fit in with a bit of spring stretching. You will have to upgrade the bulb. I did so by soldering 22 gauge brass wire to a multi voltage LED. Had to drill out the reflector and do other silly mods but it is very bright at 6.4vdc.

 

[alpg88]

I have such light, but 2 cell, tried it with 26350 cell from acebeam, did not fit, too wide.

I'm also wondering how long will your plastic reflector survive for with new brighter bulb, in my experience any high wattage bulb destroys stock mag reflector quite fast. let it run for 30 min, see if you reflector still shiny and smooth

 

[mrfixitman]

I have such light, but 2 cell, tried it with 26350 cell from acebeam, did not fit, too wide.

I'm also wondering how long will your plastic reflector survive for with new brighter bulb, in my experience any high wattage bulb destroys stock mag reflector quite fast. let it run for 30 min, see if you reflector still shiny and smooth

I haven't noticed a problem but I use metal cased emitters that only cast light 200 yards max. At 100 yards it will light up the side of a building. My A123 are larger than C in diameter but not by much. Fit right in a https://www.adorama.com/us1634597.html You can find the A123 for 50 cents each if you look around. I am using them in several lights.

 

[vicv]

I have such light, but 2 cell, tried it with 26350 cell from acebeam, did not fit, too wide.

I'm also wondering how long will your plastic reflector survive for with new brighter bulb, in my experience any high wattage bulb destroys stock mag reflector quite fast. let it run for 30 min, see if you reflector still shiny and smooth

A led should be fine. It's a power incan that melts the reflectors

 

[mrfixitman]

In my experience 26xxx cells from pretty much every manufacturer would not fit in C Maglite. at least with post 1994 Maglite, we had to bore it out with hones so cells fit.

A123 fit.

 

[alpg88]

Cool i did not know that, never used a123, they are not too popular in flashlight community, due to lower voltage and capacity,

 

[mrfixitman]

Cool i did not know that, never used a123, they are not too popular in flashlight community, due to lower voltage and capacity,

For the money and when they are in series, two or more, 8 hours might be possible. Haven't tried to check. I know they last months in the trunk waiting for use. 10,000 full cycles isn't too shabby. Less chance of fire. Sometimes sold for 50 cents each. Four bank charger is 10 bucks. Can fully charge with no penalty.

 

[vicv]

For the money and when they are in series, two or more, 8 hours might be possible. Haven't tried to check. I know they last months in the trunk waiting for use. 10,000 full cycles isn't too shabby. Less chance of fire. Sometimes sold for 50 cents each. Four bank charger is 10 bucks. Can fully charge with no penalty.

I'd love to know where you're getting these for $.50 a piece. Didn't even know they were still being made