Good idea with the Forstner bit battery removal. May be the only way to get them out without damaging the tube. When pushing the switch bulb holder assembly out after removing the snap ring it is possible for the switch button to catch on the hole on the side of the tube and break the switch. Best to depress the switch button while pushing the assy. so it doesn't catch on the hole edge going either forward or backward with it. They are very expensive to replace.
IMHO if your flashlight is damaged by the batteries, the battery manufacturers should have to replace said damaged flashlights or anything else THEIR product damaged. At no time should batteries ever leak.
The endcap and spring provide a ground to the light. If there is any corrosion or rust, it won't ground and won't turn on. I also put a small dab of lithium grease on the top and bottom threads for the head and cap to make screwing and unscrewing smoother.
The one I just disassembled was in the trunk of a car that was pulled out of a lake after 9 years of being there. Three batteries corroded so bad that it's pitted ithe medal tube and bulb assembly. The lense car was so corroded that I had to pipe wrench remove it. The the clear lense is a dark ass yellow permantly. Total turd to remove so far .
You just think you have the worst corroded maglight. I'm working on a pair. Got one opened so far. The other won't budge with a pipe wrenxh. I'm going to try heat next. Older ones like yours use a 2mm hex for the set screw. The newer ones like mine use a T8 Torx. It's hard to find one with a small shaft to fit down the hole. So a $6. one from Home Depot and some time on the bench top grinder made the shaft small enough. I chucked the tip and a bit of the shaft in the cordless drill spun it while grinding, then unchucked it and finish the bit I missed by hand. Then beat the batteries out with a piece of pvc pipe. Finished the inside with a brake hone, oiled it up. And it's as good as new. I'm hoping the 2nd one works out
Today's update. A couple of tips to pass along to those in the future who are seeking knowledge. The snap ring to remove the switch assembly from the front is difficult. If you back off the either 2mm hex screw, or the T8 Torx screw you can push down on the light bulb holder and then tighten the set screw. The lock the switch down where it doesn't block the snap ring. Then use a small pick or two to pry the ring from the groove. I found it was easier to pry one end down and push it about half way around. Then pry the other end up and work it around. It flew out of the flashlight. Then release the set screw and the switch comes out easy. No amount of beating got the last 2 batteries out. The top one wasn't corroded and came out. Next up I'm going to try drilling the battery out
Thank you for the video. I have one were acid of the battery ran through the switch unit down to the reflector. The switch has benn malfunctioning since. I will try to disassemble the thing and fit the LED to it. I read in the internet, that newer models cannot be disassembled, not even changing the LED is possible. Can anyone confirm or correct this? I am volunteer in a repair cafe and someone brought one of these.
You have to remove the rubber cap from the switch, inside the button is a small Allen nut, backed it off. Then you can slide the switch assembly out. If there is a stuck battery it's not going to happen.
Mi maglite end cup get stock so bad. Than im hace to use a hammer to remove it and i dont look nice at all but it work good and still eorking as new. By the way mi one its only 2 years old and the baterys. Blow in less than 6 months good luck for my rigth 😂
ah, childhood memories! A friend had one of those large Maglites! But in times of LED Flashlights it's pretty sad to see the bad performance of that huge Maglite compared to what a few AAA Batteries can do these days... Is it possible to replace the old bulb with something LED?
There are some crazy LED mods for it but its quite expensive. I’m glad I got it working again at least.. Dont really feel like buying a led mod right now
A simple led bulb from e-bay for £6.96 does the trick and the light is twice as bright, as for the batteries there is a conversion set that will allow AA batteries to work within a C cell torch, which I use. As the conversion is plastic they will not corrode to the inner wall of the torch. Not sure if they do a similar conversion for D cell. Apparently the reason the batteries corrode to the inside of the torch is a lack of breathability and it is recommended that you regularly open the torch up to breathe
I use a brake cylinder hone to clean the inside of mag lites
Thanks for bringing that up. I didn't know those existed. Could you give a recommendation on what kind I should get? I see 3 different types on AMZN
The look on your face when it didn’t work…. Priceless because we’ve all been there!!
Great video. Thanks
Good idea with the Forstner bit battery removal. May be the only way to get them out without damaging the tube. When pushing the switch bulb holder assembly out after removing the snap ring it is possible for the switch button to catch on the hole on the side of the tube and break the switch. Best to depress the switch button while pushing the assy. so it doesn't catch on the hole edge going either forward or backward with it. They are very expensive to replace.
I bought one of these for each car in the family.
Even Christmas gifts … backfired when my brother threw it at me … haha
Congratulations! I admire your perseverance and good humour. Not to mention your great skills and teaching ability! Many thanks 👍🏼🙏🏼
IMHO if your flashlight is damaged by the batteries, the battery manufacturers should have to replace said damaged flashlights or anything else THEIR product damaged.
At no time should batteries ever leak.
batteries are sticked inside the torched after leaking
am i the only Indian having 3d cell maglite torch 😂
The endcap and spring provide a ground to the light. If there is any corrosion or rust, it won't ground and won't turn on. I also put a small dab of lithium grease on the top and bottom threads for the head and cap to make screwing and unscrewing smoother.
I've been meaning to do this to my Maglite for years. This might be the sign I needed to finally get around to it. Thanks!
Dang, how'd you get that retainer clip out? I can't make these batteries budge and they aren't powdered like yours.
The one I just disassembled was in the trunk of a car that was pulled out of a lake after 9 years of being there. Three batteries corroded so bad that it's pitted ithe medal tube and bulb assembly. The lense car was so corroded that I had to pipe wrench remove it. The the clear lense is a dark ass yellow permantly. Total turd to remove so far .
Congrats for repairing your Maglite. I too have the same issue, but not the tools you have. I will try with what I have.
Aluminum
You just think you have the worst corroded maglight. I'm working on a pair. Got one opened so far. The other won't budge with a pipe wrenxh. I'm going to try heat next.
Older ones like yours use a 2mm hex for the set screw. The newer ones like mine use a T8 Torx. It's hard to find one with a small shaft to fit down the hole. So a $6. one from Home Depot and some time on the bench top grinder made the shaft small enough. I chucked the tip and a bit of the shaft in the cordless drill spun it while grinding, then unchucked it and finish the bit I missed by hand.
Then beat the batteries out with a piece of pvc pipe. Finished the inside with a brake hone, oiled it up. And it's as good as new. I'm hoping the 2nd one works out
Today's update. A couple of tips to pass along to those in the future who are seeking knowledge.
The snap ring to remove the switch assembly from the front is difficult. If you back off the either 2mm hex screw, or the T8 Torx screw you can push down on the light bulb holder and then tighten the set screw. The lock the switch down where it doesn't block the snap ring. Then use a small pick or two to pry the ring from the groove. I found it was easier to pry one end down and push it about half way around. Then pry the other end up and work it around. It flew out of the flashlight. Then release the set screw and the switch comes out easy.
No amount of beating got the last 2 batteries out. The top one wasn't corroded and came out. Next up I'm going to try drilling the battery out
Thank you for the video. I have one were acid of the battery ran through the switch unit down to the reflector. The switch has benn malfunctioning since.
I will try to disassemble the thing and fit the LED to it.
I read in the internet, that newer models cannot be disassembled, not even changing the LED is possible. Can anyone confirm or correct this?
I am volunteer in a repair cafe and someone brought one of these.
Did you ever find any answers?
What’s the name of the drill bit that you pulverized h there batteries with so I can pickup when I swing by Lowe’s hardware? Great video!
Thanks man! Its a forstner bir cant remember what size it was
Someone else mentioned a brake cylinder hone. That seemed like a good idea though I have never used one
How do you remove the retention ring that stops the switch assembly coming out of a magnalite?
You have to remove the rubber cap from the switch, inside the button is a small Allen nut, backed it off. Then you can slide the switch assembly out. If there is a stuck battery it's not going to happen.
Excellent! You are a great teacher!
Very Cool!
How many people own their own shop,especially with welders
more than you realize. Wire welders are cheap nowadays, bud.
Batter up!!
Good job. Fenix flashlight model PD 40 V 3 recommended ..
Mi maglite end cup get stock so bad. Than im hace to use a hammer to remove it and i dont look nice at all but it work good and still eorking as new. By the way mi one its only 2 years old and the baterys. Blow in less than 6 months good luck for my rigth 😂
ah, childhood memories! A friend had one of those large Maglites! But in times of LED Flashlights it's pretty sad to see the bad performance of that huge Maglite compared to what a few AAA Batteries can do these days...
Is it possible to replace the old bulb with something LED?
There are some crazy LED mods for it but its quite expensive. I’m glad I got it working again at least.. Dont really feel like buying a led mod right now
@@iljanster Well done on getting it to work!
@@iljansteryeah the conversions kits are pricey from what I remember.
A simple led bulb from e-bay for £6.96 does the trick and the light is twice as bright, as for the batteries there is a conversion set that will allow AA batteries to work within a C cell torch, which I use. As the conversion is plastic they will not corrode to the inner wall of the torch. Not sure if they do a similar conversion for D cell. Apparently the reason the batteries corrode to the inside of the torch is a lack of breathability and it is recommended that you regularly open the torch up to breathe
Well done!!
Good job!