Introduction: LED Zippo Flashlight

About: Hello my name is Richard. I like to take things apart and make them better. My latest builds : Chronulator with Blue LED meters (Instructable coming). Hardwired LED tailgate light strip.
This is a simple step by step guide to make your own Zippo Lighter LED Flashlight.

A few years ago Zippo had a flashlight version of their amazing classic lighter. These Zippo flashlights never really caught on, most likely because they were dim and the batteries didn't last. None the less, I thought this was a good idea and wanted to find a way to do it better.
Now I know what some of you are thinking, "Why would some one take apart a perfectly good Zippo?"  I have multiple lighters and I don't smoke. The only thing I use a lighter for is igniting fireworks and campfires. 
So, why not make an awesome flashlight ? The Zippo Lighter is an American icon and I wanted to put a new spin on it. Here is my idea, creation, and Instructables project. I hope you enjoy.  

For more information on LEDs please see the Wikipedia page ( HERE ). Truly amazing stuff. 

This is my second version of this project. If you would like to see my prototype and first try at this idea please see the last step. 

Step 1: Parts and Tools

You will need the following parts:
- Zippo Lighter
- Super bright white LED x2
- Mini Switch (I used a mini momentary switch from Radio Shack)
- Button cell battery x2
- Small gauge wire (I tore apart some old cat5 cable)
- Shrink tube
- Super glue
- Electrical tape

- Soldering Iron and solder
- Helping hands 
- Rotary cutting tool (Dremel Tool) or hacksaw
- Ruler 
- X-acto knife
- Pliers 
- Scissors
- Voltage meter (probably won't need this but I always have it around) 
- Small drill bit or needle file 

You may not need all of these tools but they may come in handy. 

Step 2: Disassembly and Zippo Modification

1- Disassembling the Zippo is extremely easy. Pull the lighter mechanism out of the case like you would if you were going to refill the fluid. The screw on the bottom comes out and the felt part slides off. Then you will find lots of cotton and the wick, this needs to go too. Save these parts you can use them later to repair other Zippos. 

2- Next, we need to remove the flint wheel to make way for the switch that will turn the LED on and off.
Use the rotary cutter (Dremel Tool) or hack saw to carefully cut off the tabs that hold the flint wheel but don't cut into the wick guard. We need this part for the switch to tighten down to.  

Step 3: LED Insert Assembly

Space is everything and we need to get not only the switch but also the LEDs in the small wick guard. 
1- Start with the LEDs. First use one of the button cell batteries to test the LEDs to make sure they are not dead before you start. Cut down the leads so that they can be soldered together in parallel. Be sure to keep in mind the polarity of the LEDs soldering one of them backwards will cause it to not work. Remember that the flat side of the LED is the cathode (negative) side. This is where this project gets tricky. Soldering these small parts without giving yourself 2nd degree burns requires a steady hand. I should have had a bit less coffee the day that I soldered this up but I got it to work eventually. 

2- The next step is to attach the negative wire that will run to the battery. 

3- Then solder the switch in place under the LEDs. 

4- Attach the positive lead that will run to the battery. 

At this point get the batteries and give it a test run. Both LEDs should light up at the push of a button. 

5- I added some heat shrink tube and super glue for good measure. The LED assembly is fragile and I did not want it to break or come loose in my pocket later on.  Give the glue some time to dry before you move on. It is  horribly uncomfortable if you get it on your fingers and if any super glue is smeared on the top of the LEDs they will not look right when you are done.  I let mine dry for an hour and a half while I polished the Zippo case and had a snack.

With this part done (and dry if you used glue) we are ready to put the mini LED assembly inside the wick guard of the Zippo.

Step 4: Put It All Together

Now you can put the LED assembly together with the lighter.
This is where I ran into a problem. The wire I used was too large to fit through the hole that the wick came through. No big problem, I used a small drill bit and a needle file to widen the hole slightly. It is important to note that this hole is actually a grommet which I believe holds the whole thing together. So don't widen too much or the grommet will break. 

Now we can put it all together. 
The wires go through the hole that the wick once passed through and the whole thing should fit together. The nut gets tightened to the front opening to hold the switch in place. 
The wires can then be connected to the battery with a bit of tape or shrink. 

Step 5: The Results

If it all came together the right you should have a working Zippo Lighter flashlight.  Show it off at the bar, tell all your friends, and please let me know what you think.

As I said at the beginning this was not my first attempt. Below are some pictures of my original prototype. I made it out of an old beat up Zippo at this point i put the switch at the bottom and used only one blue LED. 

Instructable created by RJ Koharik
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