A fun project with a Yuji 5mm 5600K High CRI LED and an old Pelican flashlight. 3 C size batteries is too much for the emitter, so I used packed aluminum foil to fill the spot where a third battery goes. I also used waxed, thick thread used for leather stitching to be able to remove the foil spacer when needed. A folded strip of foil completes the circuit from negative end of batteries to the dropin.
Dropin disassembled after destroying burnt-out bulb and removing glue
https://photos.app.goo.gl/g2E6mm44rkHsnSYk8
LED in place before pressing in rivet/spring
https://photos.app.goo.gl/k9JyWmDnFr8ZUHBE3
LED installed in plastic plug
https://photos.app.goo.gl/Jx95Ggi289GLxUuP2
Side view of completed dropin. I ended up removing the brown/gold glue and pressing the plastic plug in all the way to focus the LED
https://photos.app.goo.gl/oqtO4ngI28SAZ6sh1
LED installed, front view
https://photos.app.goo.gl/Hmg2t1bKJvWX73sq6
Image inside completed flashlight modification including batteries. Notice waxed string and foil strip to complete the circuit.
https://photos.app.goo.gl/9FtxoefnUXeom3Mg2
1:43 Video of Yuji modified Pelican
https://photos.app.goo.gl/C55tvj3YHTwqZKrm1
Dropin disassembled after destroying burnt-out bulb and removing glue
https://photos.app.goo.gl/g2E6mm44rkHsnSYk8
LED in place before pressing in rivet/spring
https://photos.app.goo.gl/k9JyWmDnFr8ZUHBE3
LED installed in plastic plug
https://photos.app.goo.gl/Jx95Ggi289GLxUuP2
Side view of completed dropin. I ended up removing the brown/gold glue and pressing the plastic plug in all the way to focus the LED
https://photos.app.goo.gl/oqtO4ngI28SAZ6sh1
LED installed, front view
https://photos.app.goo.gl/Hmg2t1bKJvWX73sq6
Image inside completed flashlight modification including batteries. Notice waxed string and foil strip to complete the circuit.
https://photos.app.goo.gl/9FtxoefnUXeom3Mg2
1:43 Video of Yuji modified Pelican
https://photos.app.goo.gl/C55tvj3YHTwqZKrm1