Convert a 3xAAA Flashlight to a Lithium 18650 Cell
Intro: Convert a 3xAAA Flashlight to a Lithium 18650 Cell
This may not pertain to all 3x AAA flashlights, but with some calipers and common sense, you can probably check for yourself.
STEP 1: The Background
I bought a cheap UV flashlight the other day to augment my pet detective toolset.
The initial problem was this: the flashlight is supposed to take 3xAAA batteries. Harummph, I say. Completely useless. I bought it anyway, figuring I'd modify it to take a useful battery type.
The initial problem was this: the flashlight is supposed to take 3xAAA batteries. Harummph, I say. Completely useless. I bought it anyway, figuring I'd modify it to take a useful battery type.
STEP 2: Battery Carrier
This is the battery carrier. It holds 3 x AAA alkaline batteries in all their overpriced, anemic glory.
Whipping out the calipers, I found the battery carrier to be 52mm in length and 22mm in diameter. So the idea was to find a rechargeable lithium battery that would fit within those dimensions.
Whipping out the calipers, I found the battery carrier to be 52mm in length and 22mm in diameter. So the idea was to find a rechargeable lithium battery that would fit within those dimensions.
STEP 3: Lithium Cells
Conveniently enough, lithium cells are labeled with their dimensions listed in millimeters.
Example:
One of the most common cells found in laptop batteries is the 18650 cell.
This means the cell is 18mm in diameter and 65.0mm in length.
Having a bunch of these, I tried to jam one in, but sadly it wouldn't fit. It was just too long.
So I went down to my local lithium battery super store, right down the street. Ermm, j/k. I went to the online electronic crap superstore based in Hong Kong. And I searched.
They had a 25500 lithium C cell, which was almost perfect. Well, just a tad too fat. I checked the internal diameter of the flashlight tube to be sure, and 22.5mm was the max it would accept.
After a few minutes it became apparent that the largest lithium battery that would fit is a 17340 cell. That would have left a horrible waste of space. I wasn't going to pay good money then wait 3 weeks for shipping time for that bad a solution.
Example:
One of the most common cells found in laptop batteries is the 18650 cell.
This means the cell is 18mm in diameter and 65.0mm in length.
Having a bunch of these, I tried to jam one in, but sadly it wouldn't fit. It was just too long.
So I went down to my local lithium battery super store, right down the street. Ermm, j/k. I went to the online electronic crap superstore based in Hong Kong. And I searched.
They had a 25500 lithium C cell, which was almost perfect. Well, just a tad too fat. I checked the internal diameter of the flashlight tube to be sure, and 22.5mm was the max it would accept.
After a few minutes it became apparent that the largest lithium battery that would fit is a 17340 cell. That would have left a horrible waste of space. I wasn't going to pay good money then wait 3 weeks for shipping time for that bad a solution.
STEP 4: Making Space
The bottom cap of the flashlight contains a spring and a plastic spacer. I removed the spring by twisting it out while pulling on it. It came right out. I tried to put it back in for the picture, but it didn't want to cooperate. So be forewarned that this might be the point of no return.
STEP 5: Dremel
I gutted the plastic to hold the battery. There is a little metal contact at the bottom, which I was careful not to maul.
STEP 6: Done
When it's done, the laptop cell fits right into the hole, buying enough space to reassemble the flashlight.
STEP 7: The Result
It's a perfect fit. The parts screw down all the way. The cell does not move when the flashlight is shaken.
STEP 8: Afterthoughts
There was one small hitch. The plastic dust from the machining worked its way into the switch. I removed the rubber dust cover over the switch in order to shake it out. I destroyed the seal in the process. Oh well.
STEP 9: Other Thoughts
I'm disappointed so far with the UV LEDs for my intended purpose. I think they emit too much visible light (as compared to a fluorescent blacklight) to be of much use in forensic work. So for now, the mystery of the unusual pet odor goes unsolved. But the investigation will continue.
8 Comments
killroytech 7 years ago
It's been a while, but: Finally, what kind of battery did you fit? You listed the batteries that didn't work! I'm all ready to do the conversion.
dragonriot 12 years ago
ScottD177 7 years ago
...18500 aren't even close - maybe with a huge amount of modifications...
mike.novo.5 9 years ago
+1
SEKJAZZ 11 years ago
AS FOR YOUR CONVERSION ARTICLE... INGENIOUS. I HAD THE SAME THOUGHTS AND WAS LOOKING ONLINE TO SEE IF ANYONE HAD MARKETED AN ADAPTER/EXTENSION TUBE TO CONVERT AAA TO A 18650... I DID FIND CONVERSION TUBES TO DOUBLE UP ON THE 18650 BATTERIES FOR UNITS ALREADY DESIGNED FOR THEM, BUT NOT THE CONVERSIONS. I CAN'T BE THE ONLY ONE WITH THE IDEA... SO I GUESS WE STAY TUNED, AND MEANWHILE, DO IT YOUR WAY FOR THOSE UNITS THAT WILL ALLOW FOR YOUR ROTO-ROOTER APPROACH. I HAVE TWO BETTER FLASHLIGHTS THAT HAVE THE SAME ANEMIC AAA HOLDER WHICH I'M NOT SURE WILL TOLERATE THE SURGERY.
THANKS.
Badboyz 12 years ago
-max- 12 years ago
MUKHRFF 13 years ago