MAG-LITE flashlights battery magazine conversion
Description
My MAG-LITE flashlight that uses 6 C type batteries was badly corroded due to battery electrolyte leaked out once the batteries inside fully used up but left very long. The corroded batteries were stuck inside the pipe. I had to remove them with brute force since all suggestion found on YouTube didn't work. It means I had to cut of the tail cap. After thorough clean up, I replaced the bulb with a LED and wanted to use AA type instead of C type batteries. Hence, I have designed a C-to-AA conversion battery magazine (you need to print 6 of them) and the tail cap. The 6EA C-to-AA conversion battery magazines can be fit in inside the aluminium pipe. Then you may put AA batteries in to the cyliner instead of C type batteries. I had to make a spring type electrical contact on the tail cap by winding a length of steel wire to a right diameter (less than the diameter of AA battery to fit in the tail cap as designed), then heated to red-glow with a gas torch then quench in a water to works like a spring. One of linear end of the spring can be put through a hole in the middle section just between the tail cap head and the thread. The wire extruded outside the tail cap can be wound up around the perimeter of the tail cap which is then became a contact to the aluminium pipe end to complete a circuit. BTW, due to the design of the tail cap you can only use AA type battery. I may consider designing a C & AA compatible tail cap in future but the design serves me good for the time being.
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