Make a $200 "tactical" flashlight for about $15

Step 2 Assemble the parts

Preparing the parts:
1. Unscrew the head of the flashlight, discard the existing bulb, and replace it with the new bulb. Screw the head of the flashlight back on.
2. Run one fender washer up against the head of the bolt. Follow the washer with a nut and tighten it firmly. Run another washer and another nut. Continue with washers and nuts until you are out of room on the bolt.
3. Cut the pipe to 4 inches long. If you think you want to make a lot of these, invest in a pipe cutting tool. The tool looks like gardening clippers and will cut through the pipe like a cold knife through cold butter - still faster and easier than a hacksaw.
3. Glue the spacer to one end of the PVC pipe. The spacer will fill the gap between the shorter batteries and the inside space of the flashlight body. It also provides the electrical connection for the positive side of the batteries. The spacer needs to be glued in place to the pipe so it remains centered inside the body. Let the glue dry for a day.

Comments

[Nerfball6]

 Could you have used smaller diameter washers that fit inside the pvc pipe, and then cut the pipe longer? No need to glue and would still be centered (provided the pvc is centered).

[dchall8]

That's a great idea!  I think it would work fine and be much faster and easier to make.  Remember to wrap the outside of the pipe with rubber bands or something to help center it inside the flashlight. 

[jackspeer]

I built the light as instructed with the exception of using the Maglite 2 D cell Aluminum body for the conversion. It was $11 more ($17) at Lowes. The light is super bright and works great.

[M1ashooter]

What did you do about the space between the pvc pipe and the ID of the flashlight. My 2D mag light and the 3/4 pvc left something missing. Pipe very loose inside mag light-will not stay centered. Tks GE

[jackspeer]

It's been so long ago that I built it that I had to look at it to reply. The 3/4 PVC is smaller than the ID of the Mag light, however, when I put it together I hold the PVC with the batteries upright and slip the flashlight housing down over it the I turn it over and screw the base on. I just did it 3 times and it lit right up each time. The spring on the base will hold it in place once it's screwed on. You got me to thinking about this. I have a piece of 1" schedule 40 in the shop so I checked. It is a perfect fit for the ID of the Mag light, however the 3/4 schedule 40 won't fit inside the 1". Tomorrow I'm going down to the HD to see if a piece of thinwall 3/4 will fit inside the schedule 40 1". My seems to be working OK as is but It would be nice if it fit tight. I'll let you know

[Grey_Wolfe]

What about placing three O-rings at regular intervals around the pvc to snug it up? Or just wrap it in a few places with electrical tape till desired diameter.

[dchall8]

Recently I started wrapping mine with rubber bands.

[karatechess]

Um... a cold knife through cold butter? Anyway, I know what you mean!{{{<br/><br/>