My T-10 OLight is a great little one battery flashlight with a strobe, but does not have the option of a crenellated bezel, so I made one. I've decided to pass the process along so that others may make one for their flashlights, regardless of brand.
Step 1: Make a 'bushing' for Your Flashlight's Head.
Then make, or have made, a 'bushing' with the inside diameter slightly smaller than the 'outside' diameter of your flashlight.
Make the outside diameter 1/4" larger than your inside diameter. This will give you a 'wall-thickness' of 1/8".
Make the bushing 3/4" long.
Not having the equipment to make this bushing, I had EDC member MattW, make it for me. (As you can see, he does excellent work.)
Since the bushing will be made with some hand work, choose a metal that is easy to file, such as aluminum, brass or bronze. I decided to go with brass.
Photo 1: You will see my T-10 OLight, (which is run by a single CR123A battery), alongside the bushing. Put a piece of masking tape over the lens for protection.
Step 2: Fitting the Bushing.
Step 3: Measure and Mark the End Ofthe Bushing.
Step 4: Hand File the Relief Portions of Your Bezel.
First take a small round, rat's tail file, and notch the end of the bushing. It's easier to start a narrow file, rather a large diameter file which slides out of place more easily. I used a 1/8" dia. file. After you've made your 6 notches with the small file, use a 1/4" dia. file and continue to file the notches 1/4" deep. Take off the masking tape from the lens and blow out any debris.
Step 5: De-burr the Sharp Edges With the Emory Cloth.
Step 6: Another View
Step 7: Another View
Step 8: Final View and Comments.
Although my cheap eBay camera doesn't show it well, the black and gold combination, looks very nice.
Now here's the important part.
When the Officer asks how the Bad Guy got his face all bloody, say: "Gee, I don't know, Officer. All I know is, this guy comes running up to me saying: 'Hold on, hold on, let me holler at you for awhile'. The next thing I know, he runs right into my flashlight. Uh..., several times. Then takes off crying! Now that's my story; and I'm sticking to it..."