Re: new set screw tool for Mag D switch - disassembled Maglite switch
Just buy a new switch assembly. They come with both wrentches and a switch.
I hope you will all excuse this necro-bump. I ended up with a Maglite (D+serial number) that I needed a switch for. I ordered one online, and it arrived without the needed wrench. Aargh. I did not want to send the flashlight to those M-folks just to have them install it, so after looking for, and failing to find, a T8 Torx driver with a thin enough shaft, I ended up at a great local hardware store, where the head tinkerer and I ended up sort of unintentionally popping the whole thing apart in an attempt to get at that infernal set screw. Now it is completely disassembled. It was worth it just to be able to replace the new set screw with the older allen wrench type set screw. I have a mixed history of putting (even simple) things back together, but I think that I will probably eventually manage. Getting the long thin metal strip back in will probably prove the most challenging part. Anyway, as long as the switch is completely in pieces, I thought that some of you might find the following photos useful, since I have never found an exploded diagram of a switch online. FYI, I had an older D-cell switch that would not fit in my D-serial number body, because the older switch was too big in diameter. The body tube has a slightly narrower outer diameter, as well.
[EDIT]
Oops. Didn't realize that there were more parts than I was aware of. As I was manhandling the assembly, getting ready to reassemble it, another sub-assembly fell out.
Here is what the main assembly looks like now. I am not taking anything else out, as it is not necessary for replacing the set screw.