Instructables
This Maglite Modification transforms the Maglite from a 19 lumen to a 900-1000 lumen monster! Many flashlight DIY'ers familiar with CPF (Candle Power Forums) may have already seen modifications similar to this, but most of the modifications on there use all web based parts, as this one uses "less" online ordering, and more localized hardware store items.

This project will run you at about $50 not including batteries. There are other cheaper DIY alternatives and production flashlights that may give you the better deal (dollars to lumens), but if you love flashlights and DIY, then this project is right for you.

This modification can be done by a "beginner" with limited flashlight knowledge, soldering skills and a basic idea on how to utilize limited resources.

Other Helpful Links (how I learned to build this): 
http://www.instructables.com/id/The-10-Watt-LED-Maglite-Cree-XM-L-Edition/?ALLSTEPS
http://laserpointerforums.com/f64/fs-1000-lumen-xm-l-t6-maglite-mod-voltage-monitor-parts-complete-light-59581.html
http://hacknmod.com/hack/how-to-1000-lumen-maglite-mod/
Candle Power Forums 
Budget Light Forums 
 
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Step 1: Parts & Tools

Orchestra Concert 131.JPG
Orchestra Concert 163.JPG
flashlight lens 010.JPG
Materials needed are as follows: 
- Maglite 2D (local hardware store)
-3/4 inch diameter pvc coupling (local hardware store) 
-3/4"x1/2" Reducer Coupling Copper (local hardware store)
-Aspherical Lens 
-LED-Cree XM-L (Bin T6 or U2- I used U2) 
-LED Driver 
-Heat Sink
-Arctic Silver Thermal Adhesive or similar item 
-Wire Stranded 22 AWG 
-O ring 50mm 
-small spring (salvage off of old/cheap flashlights)
-insulation foam (2"x2") 
-18650 Batteries - Panasonic or any reputable brand will work. Do not purchase ultrafire 18650 batteries despite their price. There are too many fakes out there and the quality of them is terrible. You can also avoid purchasing the Recharagable CR123A's shown in the pictures. [10/12/2013 UPDATE]  
-Thick Small Diameter Rubber band 
-heat-shrink tubing 

Tools:
-Hot Glue Gun 
-Soldering Iron
-Solder
-Flux
-Pliers
-Wire Cutter & Stripper 
-Alligator Clips 
-Electrical Tape 
-Torex T-8 screwdriver 
-Superglue 
-Pipe Cutter 1/8"-1-1/8" 
-Drill 
-Knife
-2x Small Staples 
-Ruler
-Sharpie
-Masking Tape
-Q-tips
-Rubbing Alcohol 

You Might Need: 
-Replacement Switch
-Dremel 
-Multimeter 
-Steel Punch 
-Digital Caliper 

Make sure you check all parts before and during assembly to make sure everything works. 

Gilcano10 months ago
Nice conversion. I have two Maglite flashlite that I would like to convert. (1-2d cells & 1-6d cells). I guess the hard part is to get the Li-Ion batteries. Very nice project. Congratulations.
An allen wrench fits into the switch assembly to remove the set screw that holds it in the tube. I want to say it's 5/32 or 3/32.
jeffmazter406 (author)  jaredshearer1 year ago
I believe that works with the older "generation" of maglites that were produced before date X (I can't remember when). I remember reading on CPF or some other website that maglite changed to using Torx T-8's instead which proved to be true in my case because it was a torx screw when I finally pulled it out.
Well, you learn something new every day! I wonder why Maglite would change something that has worked so well for so long.
jeffmazter406 (author)  jaredshearer1 year ago
Yeah, I've wondered the same thing too.
The driver comes with the output wires already connected, but where do you solder the input wires?
jeffmazter406 (author)  y0urm0msname2 years ago
That's a good question. I actually had the same question when I was looking at other posts about similar projects. The input wires are soldered on the opposite side of the input wires. The positive goes on the silver circle tab, and the negative goes on the side of the driver.(you can see it on the driver) I have included a couple picture is this comment. If you don't understand it, I have a video of the soldering process I can post on YouTube.
Jess Apartment and Light 024.JPGSolder.jpg
I FINALLY resumed this project today. Your photos were very helpful. Thanks!
Lorddrake1 year ago
how much run time do you get using the cr123a batteries?
jeffmazter406 (author)  Lorddrake1 year ago
As of right now, I have not tested the run time, but based off of previous experiences, I'd say 2 Hours on high should not be a problem. If you want to go for a longer run time, buy some Panasonic 18650 batteries, as they have significantly more mAh than what the CR123a's have. More mAh means longer run time. But remember, running high power lights for extended periods of time will make the flashlight heat up some so be careful. The most I have run it for is 30 minutes on high without any noticeable dimming.

*a member of CandlePowerForums, Jayrob, estimates that these can run 4 hours on high using 32650 batteries, which I believe is very possible.*
ProRock1 year ago
If someone wanted a cheaper alternative, you could buy a led bulb for your maglite. You won't get 900 lumen, but they're still pretty bright.

http://www.amazon.com/TerraLUX-TLE-6EXB-MiniStar5-Conversion-MagLites/dp/B001I9TI4Q/ref=sr_1_2?ie=UTF8&qid=1347938841&sr=8-2&keywords=led+maglite+bulb
jeffmazter406 (author)  ProRock1 year ago
Yup, you're exactly right! But then again there are so many other alternatives out there, not just Maglite. I was looking into Solarforce flashlights the other day- for $30 you can get an 800 lumen flashlight- and it's not the "China" lumens(as found on some cheap flashlights). It's actually supposed to be around the 800 lumens that it claims to be- and it's so much smaller than a Maglite too.
Topcat20212 years ago
Hi, Nice instructable you have made. The flashlight sure looks pretty bright and I may have to make one myself from some of the stuff that I have laying around.
I have one question though; at the end of step five you referenced a 3/8" drill bit whereas the picture seems to indicate a 3/16 or such drill bit, what is the size of the bit in question? 3/8" seems to big for the size copper fitting and the measurements given.
Thanks for the instructable and keep up the good work.
Dan
jeffmazter406 (author)  Topcat20212 years ago
Dan, Thanks for catching that mistake! I meant 1/8" Drill Bit. I have since changed it on the instructable too.
Jeffrey