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  1. #1
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    Basic Maglight bike light

    Fairly new to this (and I have done some searching already)..

    I have a 5D Maglight which is 8 yrs old sitting around doing nothing which I am interested in converting into a bike light.

    How much effort is involved to make this LED module fit in the light head?
    http://www.dealextreme.com/details.dx/sku.14413

    After cutting down the battery tube of the flashlight could it be powered by two of these in series?
    http://www.dealextreme.com/details.dx/sku.30996

    How would I charge them?

    Sorry for the newb questions...

  2. #2
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    ok it seems that the module isn't a straight drop in and the inside of the head needs to be opened up a little bit.

    Seems there are concerns on the emitter overheating as well.

  3. #3
    Carbon8er
    Reputation: El34's Avatar
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    That reflector shape looks to me like it will be way too floody and wide.
    Looks like it's a better flashlight module to me

    Look at the shape of this reflector
    This is the one I use and creates a nice beam shape for bike lighting.
    http://www.dealextreme.com/details.dx/sku.14599

    Any sort of high temp LED you attempt to use will need proper heat sinking. This means that the LED heat sink must contact a metal outer skin so that the heat can be drawn away and dissipated. I doubt that is going to happen on the maglight, but you may get lucky and it fits perfectly.
    I don't know if the maglite is a very good carcass for a bike light. I do know that it will be very heavy. Way heavier than you need for a bike light.

    Better to keep it as a 5D flashlight, IMO

    A magic shine Bike light at $77.21 is a way better route to take unless you have machines and machining skills and have the need to machine metal and make things from scratch.
    http://www.dealextreme.com/details.dx/sku.25149

  4. #4
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    As El34 says, I'm not sure that is the best solution, you certainly won't save any money by going down that route.

    So unless you are looking for a project, the magic shine, as suggested would be a better choice.

    If you do go down the mag route, look into some of the more substantial heatsink solutions available.

  5. #5
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    I have done this with a similar module and one trick to help with the heat transfer is to stuff some aluminum foil in the mag head - though this is no substitute for a properly designed light, it only helps. You may also need to file down the rim of the drop in since it will most likely stick out a bit and keep the bezel from screwing all the way down. I'd also swap the plastic lens with a glass one since it will get hot. Finally, you can mod the mag so the switch will still work, I just trimmed down the post where the bulb sits and put a screw in there as a contact. I can find some pics of the switch mod if they would be helpful - though I'd still suggest getting a better case - mine was just for a carry around light and not something that would be on all the time like a bikelight. I also used a 3XPE module which was similar in size to the one you posted.

    Mags are not bad hosts if you can get a good path for the heat to get out though. I converted a C cell mag into a nice light using a perfect XR19 drop in heat sink from sandwich shoppe (http://theledguy.chainreactionweb.co...Path=48_56_73). I recall that some people on candlepowerforums also offered services to cut fins in the magheads to help with the heat - though when you add it up, it will probably be cheaper to get a dedicated host. A buckpuck will also fit in a C cell mag for a super simple design if you try a complete DIY. Good luck!

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