Maglite modification

Maglite Modification

There are many ways to build a lightsaber, and countless addresses to buy one. A simple and inexpensive way to do this is to convert a MagLite torch. We have developed our very own method to keep it as robust and stage-ready as possible. Here we show you how it works!

Have fun building and fighting!

Required Materials

Maglite 3C
Blade holder for Maglite 3C
3,7V 18650 Li-Ion or Li-Po battery
CREE High Power LED - RGB (3W)
DIP-Switch
Heat sink ⌀ 28,5mm
Lens
Connector for Battery (2 pole)
Connector for LED (4 pole)
High power resistors 5W
Heat conductive sticky pad
Instant glue
Shrink tube
Thermal paste
Heat sink module for better protection of the lens (optional, available here)

Required Tools

Soldering iron
Braid 0,25mm²
Saw
Electrical tape
Diagonal cutter
Torx Screwdriver T8
Drill 3mm (+ drilling machine / cordless screwdriver)

Before you start, you should calculate the series resistors of the LEDs.

1. Maglite disassembly

1.1 First unscrew the reflector and the end cap. Then remove the rubber protection from the switch.

1.2 Next, loosen the locking screw of the switch with a Torx T8 screwdriver.

It can happen that the screwdriver on the shaft is too thick and has to be ground down. Sometimes a T6 screw may also be present.

1.3 Now carefully slide the switch backwards and remove the spring ring at the front.

1.4 Loosen the screw in the switch and remove the bulb socket.

1.5 Secure the switch with some electrical tape. Then remove the brown part with the diagonal cutter.

1.6 After removing the contact spring, secure the switch lengthwise.

2. Switch assembly

3. LED

4.1 Protected Assembly

Here the installation with a heat sink module for better protection is described. However, this module does not fit into the blade holders of TCSS. Alternatively, there is also an unprotected mounting option.

4.1.1 Pass the LED cables through the heat sink. Then apply thermal compound to the heat sink and lightly press on the board.

4.1.2 Attach the lens to the LED and screw the cover of the heat sink module lightly onto the heat sink.

4.1.3 Attach the finished module to the aluminium heat sink using the heat conducting pads.

4.2 Unprotected Assembly

5. Wiring

5.1 Combine, solder and insulate the negative poles.

5.2 Now solder in the series resistors, attach them to the connector and insulate them. One should pay attention to the correct color sequence to the counterpart.

5.3 Now extend the wires on the other side of the four-pole socket. Connect the negative pole of the battery plug to the negative pole of the connector. Connect the positive terminal of the battery plug to any wire of the switch.
Here the lengths of the cables should be taken into account: The wires and plugs should still protrude a few centimetres from the handle afterwards.
Also here, insulate all solder joints well.

5.4 Solder the second wire of the switch to all connections on one side of the DIP switch. Solder red, green and blue to one terminal on the other side each and insulate.

5.5 Solder the battery and the plug together.

5.6 Check the functionality of the electronics before installation. Try all colours with the DIP switch.

6. Assembly

6.1 Insert the cable harness into the Maglite from the front without the LED module and battery.

When inserting, make sure that the cables are in the cut-out shaft. Then reattach the switch.

6.2 Plug on the LED module and secure the plug with insulating tape against unintentional disconnection.

6.3 Carefully fit the plug, resistors and heat sink into the Maglite and attach the blade holder.

6.4 DConnect the battery and slide it into the Maglite. Then select a colour at the DIP switch.

6.5 Screw on the pommel, insert a blade into the blade holder, reattach the rubber cap - and you got a lightsaber!