In this howto the DoomMeister will show you how to swap the incadesent bulb in your Peli Versabrite II (flashlight) for an ultra bright LED.
Best known for their waterproof equipment cases Pelican also manufacture some very fine torches (flashlights). The only concern I have had with this particular model is the length of time that the (expensive) bulb modules last. In order to rectify this I have chosen to replace the incandescent bulb with an LED (rated 30000mcd).
Step 1: Some Weak Lemon Drink
For this modification you will need
Some sharp knives, (I used a scalpel and a Stanley knife)
A junior hacksaw
Some epoxy resin (clear is best)
A drill (perhaps)
An LED of your choice (5mm), I choose part no 55-2484 from Rapid Electronics
A quick note on the LED, I have chosen not use a current limiting resistor however one would fit in the housing if required.
Step 2: Make the First Incision
After removing the spring the first step is to remove the reflector dish. In order to this you will need to remove the existing epoxy seal (brow/grey area), this is best done with the point of a sharp blade.
Step 3: Remove the Bulb
Once the reflector is removed you can remove the bulb, If you have the patience then work away at the epoxy bonding the bulb into the housing until you have freed the bulb. Now remove the positive terminal from the housing.
If you do not have the patience then cover bulb with a cloth and SMASH it with a pair of pliers, now use a drill with a 6mm bit drill out the rest of the bulb. You should be left with a housing clean of the old bulb and any epoxy, check your LED for fit at this point. If the hole needs enlarging do this with a drill or Dremel and stone point.
Step 4: Glue Glue and More Glue
Now mix your two part epoxy, this will be used for securing the LED in the housing and reattaching the reflector. Fill the housing with epoxy and insert the LED leads first into the housing. Try to not get any on the LED face. At this point you can re-attach the reflector disc.
Step 5: Form Is Nothing Other Than Emptiness
Whilst the glue is still wet form the leads of the LED as shown in the photograph. The Cathode (sort leg) (negative lead) should be formed through the slot and around the side of the housing. The Anode (long leg) should project out of the centre of the housing. Form this around the positive terminal and insert the positive terminal back into the housing. Now make sure the the LED is properly centred before the glue sets.
Step 6: Finish
After the glue has set scrape the leads of the LED with the edge of your sharp knife to ensure good electrical contact. Now reassemble the negative spring contact.
You should now have a functioning LED bulb module for your Versabrite torch
Step 7: After Photos
As per request, here are some photos of the beam. I don't have a working bulb module to provide before shots however. Note the inner bright zone where the LED is focused and the outer zone at approximately 4 times the diameter due to the reflector.
For a bit of unscientific reference I have included a scaled shot, the surface was approximately 15mm from the front of the bezel and maybe 25mm from the nose of the LED. I have no way of measuring the apparent brightness.