Maglite cap end stuck!

[Foot]

So I recently found my mini maglite from when I was kid and I've decided to do an LED upgrade for it. Can't get the old batteries out though!
The cap end is really very stuck. I've liberally put WD-40 on the crease where it joins, it's not helped at all. Tried using some cheapo pliers and sticking an allen key in the hole to try turn it. The allen key started to bend a little before any change (I know, my allen keys are horribly cheap).

Anyone have any ideas?
I know for the price of a LED upgrade (~£10) I could buy a possibly better LED torch, but it's a nostalgic thing.

I've read elsewhere that if you leave batteries in for a long time they can leak and seize things up.. obviously I shouldn't have left batteries in, but 7 yr old me wasn't aware at the time.

Thoughts about heating/cooling the cap end? I considered using 3-in-1 oil but I'd have thought WD-40 would do a better job.

Pictures:
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[Red Herring]

Certainly on the bigger Maglights sticking the end in a cup of boiling water for a minute or so has helped in the past for me. I've not tried it on the small ones.

[Foot]

Will try this, thank you!

[Foot]

It's doesn't seem to have made any difference, it's really wedged on. How much of the end have you put in? Just the cap?

[Red Herring]

You need to heat up the outer casing of the torch so that it expands a bit and hopefully breaks the bond to the end cap. There is also a rubber ring between the cap and the casing and this will also soften up with some heat. You can quite happily dunk half the torch in the water so that as much heat as possible gets into the casing.

[Kenzie]

Try and get some plusgas on it? Is this what you are using to upgrade?

http://www.ebay.co.uk/itm/Niteize-LED-tail-switch-kit-Mini-AA-Maglite-LED-bulb-upgrade-30-lumen-/201219290102?pt=UK_SportsLeisure_Camping_LightsLan ternsTorches&hash=item2ed99ab3f6

I have a AA and AAA mini maglite and would be intersted in the mod

[Bluepete]

Two pairs of mole grips or one pair and a vice. Functionality over aesthetics!


Pete ;)

[Foot]

Try and get some plusgas on it? Is this what you are using to upgrade?

http://www.ebay.co.uk/itm/Niteize-LED-tail-switch-kit-Mini-AA-Maglite-LED-bulb-upgrade-30-lumen-/201219290102?pt=UK_SportsLeisure_Camping_LightsLan ternsTorches&hash=item2ed99ab3f6

I have a AA and AAA mini maglite and would be intersted in the mod

I was either going to use the niteize one (although I don't see the point in a click button replacement, and some reviews say the button stops working after a little knocking!)
or the more powerful terralux one:
http://www.amazon.co.uk/TerraLUX-MiniStar2-Extreme-upgrade-TLE-5EX/dp/B000B868MK

Two pairs of mole grips or one pair and a vice. Functionality over aesthetics!


Pete ;)

I'd happily do this if I had the tools! Might have to wait to I go back home for a visit..

[Nutsinatin]

Put a keyring in the end to give you better leverage by hand.

[Sid Squid]

Heat the barrel gently over the gas stove - not directly in the flame, but let it get properly heated, then put the cap in cold water, that sometimes works.

[haggis]

As you're not going to be using the old bulb or batteries......

Try to crack the siezed up threads by placing the upright torch (bulb-end down) on a solid & flat surface - like a stone floor . Then tap the end cap from directly above with a hammer, going around the edge in circles several times.
Use in conjunction with the heat/cool method.


Wait a minute here! ...... Is the beam focus end free'd up? I think you can dismantle it all from this end. I've done this with a 4C-cell Maglite.

Good luck!

[Foot]

Tried a key ring for leverage, no luck. Tried hitting it.. I'll try now to undo it all from the top up. Gonna end up breaking the thing, no doubt.

[Kenzie]

Flood it with plusgas!

[Foot]

Flood it with plusgas!

Do you sell plusgas? :smt040
Will do if I can't get to the batteries from the top easily enough :) Getting distracted with other stuff right now though. I will report back!

[Kenzie]

Just a thought really. I have Googled the issue and apparently if the batteries leak inside the torch then they pretty much bind the end cap closed. Even if you can get the cap off you may still have stuck batteries to deal with. You may destroy the torch trying to open it.

[maviczap]

Just a thought really. I have Googled the issue and apparently if the batteries leak inside the torch then they pretty much bind the end cap closed. Even if you can get the cap off you may still have stuck batteries to deal with. You may destroy the torch trying to open it.

It is a chemical attack on the alloy casing, my guess is that its effectively welded the 2 parts together

[Tomor]

My sister left batteries in her maglite and it sealed themselves in. We tried a big hammer and a block of wood to hit the batteries out but gave up as we would have trashed the torch anyway.

Sent from my magical portable device

[Foot]

None of that sounds positive. Fingers crossed

[DarrenSV650S]

I've heard that because of the extreme heat and impacts, the batteries can explode and create a pipe bomb

[Corny Gizmo]

Have you tried replacing the R/R?

[RandyO]

this is like rebuilding brake calipers, my time is worth more than the cost of a new flashlight, my research tells me $13.45 @ walmart

http://i5.walmartimages.com/dfw/dce07b8c-8390/k2-_bfa79abe-3f9f-4c8c-aaea-f962993b7ce6.v1.jpg