Don't run the risk of being stuck in the dark with no light because of a flat battery!

With this modified flashlight you will always be able to have light from its hand crank generator. Two minutes cranking provides over 20 minutes of light.

Step 1: Convertable

One of the features of this project is the ability to remove the torch from the holder as this one also had a light at its end. It has this flexibility and can be completely removed if required.

Step 2: Making the Casing

Cut a length of 3cm diameter PVC plastic pipe to 13cm long
Cut a bit out from one end for the hand crank generator to fit in (see photo).
Add a length of aluminium shimmy for a tighter fit of the generator if required.
From the other end, cut 6 cm down the length of the pipe, so it can fit over the body of a flashlight.

Step 3: Soldering the Generator

Solder on some wire leads to the hand crank generator using a soldering iron. The use of the clamping clips and magnifer, as shown in the photo made this easier.

This is the Hand crank generator used.

This is the Flashlight used:
http://www.daisojapan.com/p-51552-flashlight-2-way-3-assort-531-12pks.aspx

Step 4: Connecting the Switch

Soldier on a switch to the positive wire from the generator. Do this before fitting the switch to the handle.
Make a hole in the pvc plastic pipe and attach the switch, feed the wires though the pipe and out the front end.

Step 5: Connect Terminal Tabs

Soldier on some terminal tabs made from some copper sheet, to the end of the wires coming out the front.
Fit the tabs around a NiCd rechargeable battary in the battery holder as shown in the photo.

Step 6: Shine On

Insert the flashlight into the plastic pipe with the generator and you are good to go.

To charge the battery:

Turn the flashlight off, move the generator switch to charge position. Rotate the cranking handle for 2 minutes. This provide 20 minutes of light. When cranking of the handle has stopped, switch the generator switch off.

Having used this flashlight on a recent camping trip, I found that it was inconvenient to have to hold it while doing things like making your evening meal in the dark. Using a head light works much better around camp because you can then use both hands. I think the best use for this flashlight is as an emergency back up as you don't have to worry about it having a flat battery.