Flashlight Building and Modification

Digital Lode

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Jul 29, 2018
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Around 2015 I started building flashlights. I don't have a lot of electronics knowledge, my main interest was the amount of light that newer LED lights could put out.

I started with the cheaper stuff. There are brands which make empty flashlight bodies which can be fitted with your choice of parts. I built for fun and gave a lot of lights away to friends and family.

Last year I shelved my 15w Weller soldering iron for a 90+ watt digital iron, but not before truly learning the joy soldering flux can bring to a person's life.

Lithium Ion batteries are great power sources, as well as Li-Po cells.

You can actually buy an anti-reflective lens to allow more light to emit. A lot newer lights are equipped with this from the get go if you're not buying from your local hardware store.

Newer tech comes out every year and the LED's keep getting brighter with a better color resolution. Bright blue LED's are a thing of the past. Blue is usually encountered in light tint over 5500 kelvin. 6000+ kelvin is no longer the standard LED light color. I have lights that are between 3000k and 6000k.

Firmware for the flashlights is also improving. Some people prefer a single 100% power mode and some people prefer to program their own drivers. The space in between what is considered a normal flashlight and what is next level has really grown.

Triple LED flashlights with a direct drive driver are a fun time. They are a literal hot rod. https://imgur.com/EBSQ7Lg -- https://imgur.com/q3YT2tH

You can also add a lighted tail switch. This involves the addition of a bleeder resistor which lets a small amount of current be diverted when the light is not switched on. I use mostly mechanical switches for ease and current path.
https://imgur.com/icpTDCQ


Single LED flashlights are great for everyday or specialized use. I've built a lot of them. Even a couple green lights for coyote, racoon or hog hunting. Haven't gotten to see them in action yet though. https://imgur.com/fbAc4wK -- https://imgur.com/Zdw4dag

Triple and Quad LED flashlights that companies like Lumintop and Emisar make are great for the price. They will also burn a literal hole in your pocket, or bag if you're not careful. I have a few Lumintop FW3A lights that I bought for fun. It's nice to see what other people are making. https://imgur.com/SfZM3sX

If you want something that will really punch out there, this is the best budget for distance thrower currently on the market. I can't get the parts to build something this cool. https://intl-outdoor.com/k1-21700-thrower-led-flashlight.html

The Osram W1 CSLNM1.TG is currently my favorite LED. It is a 1mm square LED on a 3mm die. Capable of a tighter beam pattern and higher candela than other LED's. It has to be limited the current fed to it so it doesn't overdrive and tint shift.

The Osram W2 CSLPM1.TG is my other favorite LED. It is a 2mm square LED on the same 3mm die. While it can be fed with a direct drive, it also reportedly does better when limited. One of my daily carry lights is built with this and it really punches a hole in the darkness.

I work nightshift if you haven't guessed.
 
Good hobby would never even know where to start.

The idea you can harness the power of the sun and keep it in your pocket is a good starting point.

You don't have to spend $100 for a good flashlight. There's a deal on mediocre flashlight on Amazon right now for 10.99 USD. It's the Tacklife LED flashlight and it come with a battery and onboard charging. It's a decent thrower but a little too big to put in your pocket. I also have my reservations about the switch which was used. But I'm sure it will work fine for awhile. Just not as sturdy as the Omten switches.
 
Awesome write-up! Thanks for letting us in to something that lights up your life. :highly_amused:
 

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