Introduction: How to Repair Flashlight Switch (Fix Tailcap Switch)

Hello, Everyone!

in This Instructable, I will share with you How to Fix the Mechanical Switch in Flashlights (this method Should Work on Most flashlights except the Old Models like Maglite )

I will demonstrate the Repair on Skywolfeye Zoomable Torch

ok, Let's Begin :)

Step 1: Gently Pull the Rubber Cap

Picture of Gently Pull the Rubber Cap

*The Switch in this torch is Press-fitted, if The Switch in your Torch is Screwed in Then unscrew it first, Then pull the Rubber Cap

Step 2: Use Something Thin But Not Sharp to Push the Plastic Housing Out of the Tailcap , Tap It Gently

Picture of Use Something Thin But Not Sharp to Push the Plastic Housing Out of the Tailcap , Tap It Gently

Step 3: Pull the Switch From the Plastic Housing

Picture of Pull the Switch From the Plastic Housing

Step 4: Measure the Resistance of the Switch to Make Sure That the Problem in the Flashlight Is Caused by the Switch Not From the Pill

Picture of Measure the Resistance of the Switch to Make Sure That the Problem in the Flashlight Is Caused by the Switch Not From the Pill

Step 5: Use a Thin Object to Pry Open the Switch Through the Holes on the Sides

Picture of Use a Thin Object to Pry Open the Switch Through the Holes on the Sides

if your Switch Does not Have Holes on the Sides Then use Something very thin

like a flat head screwdriver to wedge between the Side Crack of the switch (But Be careful not to cut yourself)

Step 6: After Opening the Switch , Clean Its 3 Pins Very Well

Picture of After Opening the Switch , Clean Its 3 Pins Very Well

Use a metal File or Sand Paper to Remove any Rust from The Surface of the Conductors.

but don't file it too much, Just Scratch The Surface.

Step 7: After Cleaning the Pins, Reassemble the Switch

Picture of After Cleaning the Pins, Reassemble the Switch

Step 8: Measure the Resistance of the Switch

Picture of Measure the Resistance of the Switch

Before the Repair The Resistance was 13 ohm, After the Repair, it Became in the Range of 0.01-0.1 OHM , Which means it became as good as new.

Step 9: Put the Repaired Switch Back in the Plastic Housing

Picture of Put the Repaired Switch Back in the Plastic Housing

Step 10: Insert the Rubber Cap

Picture of Insert the Rubber Cap

Step 11: Insert the Plastic Housing , Then Tap It Lightly to Secure It in the Tailcap

Picture of Insert the Plastic Housing , Then Tap It Lightly to Secure It in the Tailcap

Step 12: Connect the Tailcap to the Flashlight and Test It

Picture of Connect the Tailcap to the Flashlight and Test It

it Should Work :)

For More Details, Watch the Eembedded Video.

I hope This instructable was helpful to you

Thank you for Reading.


Thulfiqar Ali

Comments

tytower (author)2017-08-16

If you could get some solderon the cleaned contacts your repair might last a lot longer

Thulfiqar (author)tytower2017-08-18

Thanks for the tip :)

Swansong (author)2017-08-16

Neat, I'm glad you could fix it :)

Thulfiqar (author)Swansong2017-08-16

Thank you swansong <3

About This Instructable

321views

8favorites

Bio: Hi , My name is Thulfiqar :)
More by Thulfiqar:How to Repair Flashlight Switch (Fix Tailcap Switch)
Add instructable to: