I present my second small two part AAA LED torch (flashlight) host.
The internals needed are from an MXDL 3W Luxeon LED light (shown in one of the pictures).
To build this torch the following is required:
1. Plastic AAA 2 Torch Head (included),
2. Plastic AAA 2 Torch Tail (included),
3. MXDL 3W Luxeon LED AAA light (not included, but available on ebay and should only cost a few dollars so i advise ordering more than one).
4. Metal strip, 0.1mm thick, 5mm wide and 120mm long to create an electrical path from the negative end of the battery to the LED unit. (not included, use copper or aluminium if available but steel will also work)
To fit the electrical path strip: find it's midpoint then bend the strip up at 90 degrees 5mm from either side of the midpoint using the edge of a ruler to form a U shape.
Using a large flat bladed screwdriver press the strip into the Tail Unit making sure it rests on the hole's bottom and is correctly orientated with the cut outs.
Then press fit the spring from the MXDL torch into the tail so that it is retained in the base.
Install the battery to hold the sides of the strip in place and bend the protruding strip ends outwards, pressing them flush with the Tail Units top.
Then trim the strip ends to finish within the inner perimeter of the Tail Units threads.
The final version of this torch will be offered in silver and will not require the electrical path strip.
However due to casting shrinkage issues affecting the close tolerences required for the threads and fitting of internal components I can't offer a silver option until these issues are fully solved.
Despite the MXDL's low price it is a very durable and relatively bright little light with the components easily removed from the doner light.
However if damage or failure were to occur, due to the ease and cheapness of replacements, the host light can be brought back to life without great expense or drama.
There are some more photos of this object and other examples of my work, both 3D printed and otherwise, on my 'Tofty' facebook page