Instructables
This instructable will show you how to build a LED flashlight.
 
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Step 1: Tools and materials needed

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Tools
Soldering Iron
Hot Glue gun
Nail clippers
Wire strippers
Marker

Materials
1/2" Pipe Cap
4.5" x 1/2" Threaded Pipe
1/2" to 3/4" Pipe adapter
Perforated circuit board
Spring
Wire
Solder
Hot glue sticks
10 5mm LEDs
Sheet of foam
Shears or Dremel with cutting wheel

Step 2: Cut the perforated circuit board

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Cut a circle out of the perforated circuit board that will fit inside the pipe adapter.

Step 3: Dry fit the LEDs

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Put the LEDs into your circular circuit board to see how they fit.  Then trim the LED leads and leave the longer lead slightly longer.

Step 4: Solder the LEDs

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First solder the LEDs to the circuit board.  Then solder all the positive and all the negative LED leads together.  Test your LED board with a 3 volt power source to make sure you have soldered the LEDs correctly.

Step 5: Create a spring

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Create a spring for the flashlight.

Step 6:

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Screw your LED board into the steel adapter.  Leave an uninsulated wire connected to the negative connection of the LED board hanging so it makes contact with the steel adapter when screwed in.

Test your connections.  If it is working properly make a contact with a washer and some solder.  Fill the area behind the contact with hot glue.

Step 7:

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Cut some foam spacers that go between the battery and the contact point.  The spacers create a switch that is on when the adapter is tightened.

Step 8:

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Tweak the number of foam spacers so that the flashlight turns on only when the adapter is tightened.
Nemesistant2 years ago
Working on making one of these out of copper pipe and then reacting it with zinc to give it a nice brass layer and more of a steampunk look.
tyler3030473 years ago
YAY something that can show you path AND maim someone.
jk a very very useful instructable.
try bringing this on an airplane
Nyanman3 years ago
sweet!
both a flashlight AND a holdout weapon.
seriously, how much does it weigh?
kurshiukas4 years ago
Its awsome!!!!!!!!!!
Wasagi4 years ago
Nice, I was toying around with the idea of making something like this with a shower head, but I never go around to it. Nice work!!!
DaPope4 years ago
Very cool, I picked up the pipe yesterday. Just gotta get some LEDs and we're in business. My wife also thinks it's really cool and wants me to make her one to keep in her car!
rossjima4 years ago
I'm constantly crushing, breaking flashlights on the farm. I have to make one of these. What about extending it so it holds more batteries? Would that make it brighter. It would up the voltage for sure but I don't know much about how leds behave and are speced.
Skyfinity4 years ago
http://blog.makezine.com/archive/2010/08/flashlight_from_galvanized_iron_pip.html
 
Congratulations on bing featured on the Make: Magazine blog!!! Way Cool.
qxnixrfnaozqqx (author)  Skyfinity4 years ago
Awesome!
omnibot4 years ago
Sweet flashlight, it would really come in handy in those dark nights when someone is following you. A bit of blackpaint and it's done.
OW. Could you imagine how much it would hurt to get cracked over the head with this thing?
Just like a maglight beat-stick... only more brutal.
What sucks the most is you could weld on spikes to this one if you wanted to!
just what i was thinking!
I smell concussion(s)!
hahaha
lol
Just use black pipe.
swinfos4 years ago
sorta looks like a lightsaber
This is brilliant in it's straight-forward and effective design.
brahmdanger4 years ago
nm, i didnt realize that the pipe itself was the negative conductor. Here is the one i made. thanks again!  
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qxnixrfnaozqqx (author)  brahmdanger4 years ago
Well done.
brahmdanger4 years ago
this is an awesome idea, im currently trying to biuld a flashlight just like this but im having trouble completing the circuit on the negative end of the batterries, could you post more details about how you wired this? Thanks for the great instructable!
qxnixrfnaozqqx (author)  brahmdanger4 years ago
The trick is to conduct electricity from the negative terminal of the battery through the flashlight. This is done by putting a spring inside the case which touches the negative side of the battery to the steel case. Diagram attached.
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tokymaru4 years ago
.....can anyone say pipe bomb?
pipe bomb. ther i said it are you happy now lol
Little bit, yeah.
I dunno, looks kinda flimsy XP (for anyone thick enough that was a JOKE!)
Yeah and really light and portable.
Nucleus4 years ago
Neat design
Very cool and almost steampunk. I think I know what I am going to make.
junits154 years ago
very cool!
Looks awesome! ...And kind of like a light saber. haha.
Culturespy4 years ago
Talk about industrial strength! Nice job!