Introduction: 8000 Lumen LED Dewalt Flashlight Mod

Picture of 8000 Lumen LED Dewalt Flashlight Mod

This instrucable will show you how to modify a Dewalt 18v incandescent cordless light. The modification entails adding a 18V to 35V dc/dc step-up converter and a 8000 lumen LED.

Step 1: Materials



Dremel with cutting tool - To check out my homemade All purpose Dremel blade click HERE

Soldering Iron and solder

Wire Strippers

Skrew Driver - Flat head and torx

DMM - Digital Multimeter


100W - 8000 lumen LED - Ebay

18V - 35V dc/dc step-up Converter 150W

Dewalt 18V cordless Light

Thermal Compound

Step 2: Disassembly

Picture of Disassembly

- First take the battery out of the light to be safe

- Take the two torx screws out from the light head. The top torx screw has a pin in the middle which can be snapped off using pressure and a small flat head screwdriver if you don't have the right bit.

- Unscrew the lens

Step 3: Mounting the Dc/dc Converter and LED

Picture of Mounting the Dc/dc Converter and LED

- Drill a hole in the top of the Light this is used to feed wires into the light.

- Solder the LED onto the output wires coming from the converter. Make sure the polarity is correct on the LED.

Step 4: Shaping the Heatsink

Picture of Shaping the Heatsink

This LED gets extremly hot! Be carful!

- Cut, Grind, File the heat sink to fit inside of the light housing

Step 5: Putting It All Back

Picture of Putting It All Back

- Once the heat sink is shaped to fit inside the housing, use thermal compound to adhere to the LED. This helps transfer the heat away from the LED.

- Screw the side covers together

Step 6: Fitting the Lens

Picture of Fitting the Lens

- Cut the Lens using a Band saw or Grinder

- Screw the lens on to tighten the LED

Step 7: The Video


PaxDesigns (author)2014-06-05

Any problem with heat?

Ryan Depace (author)PaxDesigns2014-06-05

Yes it does get very hot. I can't leave it on for a long time

Splaxx (author)2014-06-02

That's not a flashlight... that's a headlight.

Very Nice!

craftclarity (author)Splaxx2014-06-03

^^^ What Splaxx said.

GuyTech797 (author)2014-05-30

Is it safe to put themain circuit on the outside considering it was waterproof before?

Ryan Depace (author)GuyTech7972014-06-01

Hey guytech,

The light before hand I wouldn't say is completely waterproof considering there are no seals. The circuit that I added is not waterproof, but it would be cool to build an enclosure. Printing one using a 3D printer would be awesome.

Ryan Depace (author)2014-05-28

Haha thanks man!

HawaiianGuy (author)2014-05-28

Freaking awesome, that's all i can say:)

About This Instructable




Bio: I live in New England and currently have two degrees, one in Electronic Engineering and the other in Electrical Technology. I love building and tinkering ... More »
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