Ripper
10-19-2011, 02:17 PM
I was starting myself a saber, and thought I would make a tort on how I make my flashlight battery holders. Most of the flashlights I used are a 4 volts, with 3 AAA bats in them.
I hope I do this right!
OK I decided to make a lil tort on how to make a battery holder out of a LED flashlight. Like the pics below.
http://i1134.photobucket.com/albums/m610/rippergary/pommal.jpg
http://i1134.photobucket.com/albums/m610/rippergary/Litepic.jpg
http://i1134.photobucket.com/albums/m610/rippergary/saberpommal.jpg
http://i1134.photobucket.com/albums/m610/rippergary/IMG_20110915_201048.jpg
OK
1. I take my flashlight.
http://i1134.photobucket.com/albums/m610/rippergary/flashlightspic.jpg
2. I then take out the batteries, and hallow out the inside.
I like to take the socket set extension and just push out the LED holder and board.
http://i1134.photobucket.com/albums/m610/rippergary/step1.jpg
http://i1134.photobucket.com/albums/m610/rippergary/step2.jpg
http://i1134.photobucket.com/albums/m610/rippergary/step3-1.jpg
http://i1134.photobucket.com/albums/m610/rippergary/step4.jpg
3. After the flashlight is hallowed out. I start to make the positive connection.
I take a water bottle cap and cut the edges to fit the inside of the flashlight.
The inner ring is normally a good guide for this. Mine is a bit messy this time, but I will be covering it all with hot glue.
http://i1134.photobucket.com/albums/m610/rippergary/step5.jpg
http://i1134.photobucket.com/albums/m610/rippergary/step6.jpg
http://i1134.photobucket.com/albums/m610/rippergary/step7.jpg
http://i1134.photobucket.com/albums/m610/rippergary/step8.jpg
4. Next I cut a small hole in the center of the cap for the connection. I will be using a small screw for the connection.
http://i1134.photobucket.com/albums/m610/rippergary/step9.jpg
Hole
http://i1134.photobucket.com/albums/m610/rippergary/step10.jpg
http://i1134.photobucket.com/albums/m610/rippergary/step11.jpg
5. Now I solder the positive wire to the nut.
http://i1134.photobucket.com/albums/m610/rippergary/step12.jpg
6. Fit the whole set up in the flashlight to see how well it fits. Mine fits great, so now to start on the negative wire.
http://i1134.photobucket.com/albums/m610/rippergary/step13.jpg
7. I soldered the neg. wire to the metal ring they have in the flashlight for there ground and use it as the same. I then place it in the flashlight. Again this will be covered in hot glue, so I am not using any heat sink. I normally do for other projects.
http://i1134.photobucket.com/albums/m610/rippergary/step13-1.jpg
http://i1134.photobucket.com/albums/m610/rippergary/step14.jpg
It’s basically all done. I just need to do a test, aaannnnnddddd! IT WOKS!!! 4.7 volts!
http://i1134.photobucket.com/albums/m610/rippergary/step15.jpg
Now to clean up any mess and add some hot glue for safety and it is ready for a saber like this below!
http://i1134.photobucket.com/albums/m610/rippergary/IMG_20110828_215311.jpg
http://i1134.photobucket.com/albums/m610/rippergary/IMG_20110828_234158.jpg
http://i1134.photobucket.com/albums/m610/rippergary/Fullhiltlit-1.jpg
http://i1134.photobucket.com/albums/m610/rippergary/Litonstand.jpg
Thanks for reading! I hope this will give you guy’s new ideas.
I hope I do this right!
OK I decided to make a lil tort on how to make a battery holder out of a LED flashlight. Like the pics below.
http://i1134.photobucket.com/albums/m610/rippergary/pommal.jpg
http://i1134.photobucket.com/albums/m610/rippergary/Litepic.jpg
http://i1134.photobucket.com/albums/m610/rippergary/saberpommal.jpg
http://i1134.photobucket.com/albums/m610/rippergary/IMG_20110915_201048.jpg
OK
1. I take my flashlight.
http://i1134.photobucket.com/albums/m610/rippergary/flashlightspic.jpg
2. I then take out the batteries, and hallow out the inside.
I like to take the socket set extension and just push out the LED holder and board.
http://i1134.photobucket.com/albums/m610/rippergary/step1.jpg
http://i1134.photobucket.com/albums/m610/rippergary/step2.jpg
http://i1134.photobucket.com/albums/m610/rippergary/step3-1.jpg
http://i1134.photobucket.com/albums/m610/rippergary/step4.jpg
3. After the flashlight is hallowed out. I start to make the positive connection.
I take a water bottle cap and cut the edges to fit the inside of the flashlight.
The inner ring is normally a good guide for this. Mine is a bit messy this time, but I will be covering it all with hot glue.
http://i1134.photobucket.com/albums/m610/rippergary/step5.jpg
http://i1134.photobucket.com/albums/m610/rippergary/step6.jpg
http://i1134.photobucket.com/albums/m610/rippergary/step7.jpg
http://i1134.photobucket.com/albums/m610/rippergary/step8.jpg
4. Next I cut a small hole in the center of the cap for the connection. I will be using a small screw for the connection.
http://i1134.photobucket.com/albums/m610/rippergary/step9.jpg
Hole
http://i1134.photobucket.com/albums/m610/rippergary/step10.jpg
http://i1134.photobucket.com/albums/m610/rippergary/step11.jpg
5. Now I solder the positive wire to the nut.
http://i1134.photobucket.com/albums/m610/rippergary/step12.jpg
6. Fit the whole set up in the flashlight to see how well it fits. Mine fits great, so now to start on the negative wire.
http://i1134.photobucket.com/albums/m610/rippergary/step13.jpg
7. I soldered the neg. wire to the metal ring they have in the flashlight for there ground and use it as the same. I then place it in the flashlight. Again this will be covered in hot glue, so I am not using any heat sink. I normally do for other projects.
http://i1134.photobucket.com/albums/m610/rippergary/step13-1.jpg
http://i1134.photobucket.com/albums/m610/rippergary/step14.jpg
It’s basically all done. I just need to do a test, aaannnnnddddd! IT WOKS!!! 4.7 volts!
http://i1134.photobucket.com/albums/m610/rippergary/step15.jpg
Now to clean up any mess and add some hot glue for safety and it is ready for a saber like this below!
http://i1134.photobucket.com/albums/m610/rippergary/IMG_20110828_215311.jpg
http://i1134.photobucket.com/albums/m610/rippergary/IMG_20110828_234158.jpg
http://i1134.photobucket.com/albums/m610/rippergary/Fullhiltlit-1.jpg
http://i1134.photobucket.com/albums/m610/rippergary/Litonstand.jpg
Thanks for reading! I hope this will give you guy’s new ideas.