Author Topic: 4D K2 Magmodding step by step with a megabyte of pics to show you how.  (Read 19831 times)

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Offline 3rd_shift

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See that 4D magled at the top?

That's the one getting modded today.

Time to get some tools out.


You need to make your reflector look like this nice and neat.


Take off the switch boot without tearing it up.


Use a 5/64rths allen wrench to loosen the switch assembly like this.


Use something long to gently send the loosened switch assembly down and out of the barrel.


Use that 5/64 allen wrench again to take off the switch assembly roller.


The bulb holder guts easily come out now.


Cut off the top of the plastic bulb tower and bend the (-) tab over like this.
I already pre-soldered it for a later step.


Cut a 4 inch (-) wire and a 5 inch (+) 22-24 guage wires of different colors.
Strip off thier ends leaving about 3-5 millimeters of bare wire.


This is important.
Get some extra rosin flux and and apply it to where the wires are going.


Solder the wires to the chopped switch assembly like this.


These parts now need to come together.
A 1 ohm 5 watt rated resistor will be used this time around.
The heatsink came from here.
 http://www.candlepowerforums.com/vb/showthread.php?t=120417
The UWON binned K2 led came from www.photonfanatic.com


Mix up some Arctic Alumina and apply it to the center of the heatsink where the led is going and stick on the led.


Make sure to "bulls-eye" the led dead center like this when sticking it on and let the adhesive set.


Re-install the wired switch assembly.


Cut another 2 inch piece of 22-24 guage wire and strip off 3-5 millimeters off it's ends.


Bend the led's leads well clear of the heatsink.


Without shorting the battery, use a 3 volt battery to find out the led's polarity if you don't already know it.


Put that 2 inch pice of wire through the heatsink on the (-) side of the led like this.
.

Watch how the resistor was installed.
Regular 2 part epoxy was used.
The (-) input side is closest to the heatsink.
The (-) going to the led is cautiously away from the heatsink with a piece of paper inserted over there.
The other end of that 2 inch wire then got soldered to the resistor's "output" side leading to the led's (-).
Allow the resistor's adhesive time to set.


Time to put the heatsink assembly into the flashlight.


Put the red wire through the heatsink to be soldered to the led's (+) on top.
Solder the (-) wire to the resistor's (-) input side nearest the heatsink.


Solder the red wire to the led's (+).


"Deep breath"
Load the batteries into the tube without the tailcap and measure the current with a dc ampmeter.
1.2 amps looks good for this UWON bin 1.4 amp rated Lumileds K2 led.
It's not overdriven even with fresh batteries.


Now that we know it works, now we can make a mess like this.
This step is necessary for the heatsink to transfer the led's heat to the aluminum body of the flashlight.
Something that a stock Magled can't do very good.
This is why Magleds go dimmer after a few minutes from getting hot.
This flashlight in it's modded state will now, stay at full power far longer without getting too hot.


Now bend the wires something like this to get them to squish in.


Push the led heatsink assembly into the barrel as far as you can.
It stopped just 1 millimeter short of where it was supposed to go in this case.
Nice tight fit as it should be.


I used a pipe with a hollow plastic end on it to drive the heatsink the rest of the way in.
Notice how some of the heatsink grease squished out once the heatsink was all the way in.


Moment of truth!
Magled reinstalled into another 4D light on the left with new batteries.
K2 Magmod on the right kicking it's butt! :)
The Magled hasn't even gotten warm enough to dim yet and it's still losing!


As you can see, I have been doing this for a while.


« Last Edit: March 31, 2007, 06:59:38 PM by 3rd_shift »
plantruler@hotmail.com
is my email and paypal address. :)
Observe and report what you saw with a good flashlight. ;)

Codeman

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Re: Magmodding step by step with a megabyte of pics to show you how.
« Reply #1 on: December 10, 2006, 12:54:37 AM »
Deleted
« Last Edit: February 02, 2007, 11:16:52 PM by Codeman »

Offline duff72

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Re: Magmodding step by step with a megabyte of pics to show you how.
« Reply #2 on: December 10, 2006, 02:17:03 AM »
thanks for the info  :headbang:
surefire u2, e2d, 6p, 6pn, l1, e1e, 9an,g2,  tigerlight 375 lumen,arc AAA premium,jetbeam mkII,eternalight max,marine x ray,raven,derringer, maglite 2 3 4 5 &6 d cell 2,3&4 c cell, inova 24/7, X1, thor10mcp,ae 24 w hid,streamlight firebox,gladius,fenix p1,lop s.e., photons galore & many others

Offline Concept

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Re: Magmodding step by step with a megabyte of pics to show you how.
« Reply #3 on: December 10, 2006, 09:18:26 AM »
Wow nice info. Might be a project for next year if I am brave enough.
Happy to be here.

Offline Geologist

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Re: Magmodding step by step with a megabyte of pics to show you how.
« Reply #4 on: February 18, 2007, 01:44:47 PM »
Should have done this in the past -

This thread is now a *STICKY*  :headbang:
Dragon, Ti, and Classic Chammies, Blk, Bare, & Brass LCs, Blk & Bare LHs, X990, Rayzorlite, The Torch, Mag85, MagGH24, SF C3, C2, 6P, G2, & Winelights, Peak Caribbean, Pacific, McKinnleys, + more , Exolion Ti, Orb Raw NS, SS Gatlight, Eternalights, Nuwai QIII, Inova X5THAs, X1, ARCs, + more?

Offline Rebel

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Re: Magmodding step by step with a megabyte of pics to show you how.
« Reply #5 on: February 18, 2007, 02:03:04 PM »
Cool!  :thumbup: :headbang:

Great tutorial with nice pictures.

I wonder if doing that to my Maglite might void my warranty?  :icon_scratch: :laughing7:
“The conscious and intelligent manipulation of the organized habits and opinions of the masses is an important element in democratic society. Those who manipulate this unseen mechanism of society constitute an invisible government which is the true ruling power of our country." - Edward Bernays

Offline Geologist

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Re: Magmodding step by step with a megabyte of pics to show you how.
« Reply #6 on: February 18, 2007, 02:09:39 PM »
Ya never know - Maglite might send ya a new lightbulb or something!
Dragon, Ti, and Classic Chammies, Blk, Bare, & Brass LCs, Blk & Bare LHs, X990, Rayzorlite, The Torch, Mag85, MagGH24, SF C3, C2, 6P, G2, & Winelights, Peak Caribbean, Pacific, McKinnleys, + more , Exolion Ti, Orb Raw NS, SS Gatlight, Eternalights, Nuwai QIII, Inova X5THAs, X1, ARCs, + more?

Offline Lips

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Re: Magmodding step by step with a megabyte of pics to show you how.
« Reply #7 on: February 18, 2007, 02:44:08 PM »
I've looked at this post several times while working on Mags!


 :thumbup:
Fire Foxes FF4 in stock and ready to ship.
You can send me a PM me here at site or contact me directly at FireFoxes@comcast.net for information.
Prices and info at the top of this post:
http://flashlight-forums.com/index.php?topic=13795.0

Offline 3rd_shift

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Re: Magmodding step by step with a megabyte of pics to show you how.
« Reply #8 on: February 20, 2007, 10:28:18 PM »
Here is a breakdown of the parts prices as of the date of this post.

K2 UWON binned Led= $5
Heatsink= $8
Maglite 4D= $20
(I found mine at Lowes last December on sale for $9.97. ;)
Resistor= 50 cents.
Other smaller expense materials= $5 maximum.
Looking at about $38 - $40 (typically) to do one of these yourself.

If you don't have a Dremel to take off the bulb tower's top, a metal cutting hacksaw can be used instead. 
plantruler@hotmail.com
is my email and paypal address. :)
Observe and report what you saw with a good flashlight. ;)

Offline fläshgreëniè

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Re: Magmodding step by step with a megabyte of pics to show you how.
« Reply #9 on: February 21, 2007, 08:29:58 AM »
nice inspiration!!!  :D makes me want to get out all the mod stuff I have been accumulating the past year...   :-[:P
good job. 3rd shift!!! :thumbup: :thumbup: :thumbup:

Mags are probably the cheapest way to make mistakes if you want to start modding... ;)

Offline Ledean

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Re: 4D K2 Magmodding step by step with a megabyte of pics to show you how.
« Reply #10 on: April 10, 2007, 02:24:29 PM »
Great post .
Thanks.

Offline footballyears.net

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Re: 4D K2 Magmodding step by step with a megabyte of pics to show you how.
« Reply #11 on: October 11, 2007, 12:58:16 PM »




*MR Bulk says, "Duplicate of the huge row of pictures deleted, but No text was harmed in the execution of this operation."
« Last Edit: October 11, 2007, 11:05:02 PM by MR Bulk »
football

Offline 45/70

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Re: 4D K2 Magmodding step by step with a megabyte of pics to show you how.
« Reply #12 on: October 12, 2007, 12:40:59 AM »
Ya, that's just what I thought he said!  :thumbup:

Dave
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Offline 3rd_shift

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Re: 4D K2 Magmodding step by step with a megabyte of pics to show you how.
« Reply #13 on: October 13, 2007, 01:23:04 AM »
Hey football, if you have any questions about how to do that magmod that I didn't or forgot to cover, please send me a pm.
I'm happy to assist. :)
plantruler@hotmail.com
is my email and paypal address. :)
Observe and report what you saw with a good flashlight. ;)

Offline gyssedk

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Re: 4D K2 Magmodding step by step with a megabyte of pics to show you how.
« Reply #14 on: November 16, 2007, 10:18:28 PM »
he he just checked the price on a 4D Maglite here in Denmark.

75 bucks!!! things from your part of the world tend to bea little expensive over here. but i would still like to try that mod.


Claus