Maglite cap end stuck! - SV650.org

30-11-14, 01:39 PM

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:
IMAG1411.jpg
IMAG1412.jpg

Red Herring · 30-11-14, 01:47 PM

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.

30-11-14, 01:50 PM

Will try this, thank you!

30-11-14, 01:59 PM

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 · 30-11-14, 02:32 PM

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 · 30-11-14, 03:01 PM

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

http://www.ebay.co.uk/itm/Niteize-LE...item2ed99ab3f6

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

Bluepete · 30-11-14, 03:24 PM

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

Pete

30-11-14, 03:28 PM

Quote:

Originally Posted by Kenzie

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

http://www.ebay.co.uk/itm/Niteize-LE...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-Min.../dp/B000B868MK

Quote:

Originally Posted by Bluepete

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 · 30-11-14, 07:06 PM

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

Sid Squid · 30-11-14, 11:38 PM

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.

30-11-14, 01:39 PM	#1
Foot Guest Posts: n/a	Maglite cap end stuck! 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: IMAG1411.jpg IMAG1412.jpg

30-11-14, 01:47 PM	#2
Red Herring Member Mega Poster Join Date: Dec 2007 Posts: 2,708	Re: Maglite cap end stuck! 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.

30-11-14, 01:50 PM	#3
Foot Guest Posts: n/a	Re: Maglite cap end stuck! Will try this, thank you!

30-11-14, 01:59 PM	#4
Foot Guest Posts: n/a	Re: Maglite cap end stuck! 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?

30-11-14, 02:32 PM	#5
Red Herring Member Mega Poster Join Date: Dec 2007 Posts: 2,708	Re: Maglite cap end stuck! 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.

30-11-14, 03:01 PM	#6
Kenzie Member Join Date: Feb 2011 Location: Ipswich, Suffolk Posts: 820	Re: Maglite cap end stuck! Try and get some plusgas on it? Is this what you are using to upgrade? http://www.ebay.co.uk/itm/Niteize-LE...item2ed99ab3f6 I have a AA and AAA mini maglite and would be intersted in the mod __________________ Flickr https://www.flickr.com/photos/39887875@N06/ Last edited by Kenzie; 30-11-14 at 03:08 PM.

30-11-14, 03:24 PM	#7
Bluepete Member Mega Poster Join Date: Sep 2005 Location: Ex motorcyclist Posts: 1,961	Re: Maglite cap end stuck! Two pairs of mole grips or one pair and a vice. Functionality over aesthetics! Pete __________________ https://www.facebook.com/pete.philli...04?ref=tn_tnmn

30-11-14, 07:06 PM	#9
Nutsinatin Member Join Date: Jan 2013 Location: Lyne, Surrey Posts: 570	Re: Maglite cap end stuck! Put a keyring in the end to give you better leverage by hand. __________________ Blue K9 Pointy - Squished by a car/kerb/wall Blue K9 Pointy #2 - Nearly at 120,000 miles!

30-11-14, 11:38 PM	#10
Sid Squid No, I don't lend tools. Mega Poster Join Date: Jul 2003 Location: Skunk Works, Nth London Posts: 8,680	Maglite cap end stuck! 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. __________________ If an SV650 has a flat tyre in the forest and no-one is there to blow it up, how long will it be 'til someone posts that the reg/rec is duff and the world will end unless a CBR unit is fitted? A little bit of knowledge = a dangerous thing. "a deathless anthem of nuclear-strength romantic angst"

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