by rstephen4048, published
Here is an LED flashlite that you can build several ways. It has a top, body and a cover for the battery(s). There are two top files â€“ one for a 5mm LED and one for an 8mm LED. The body has a hole for a sub-mini slide switch and a fitted opening for a 9V battery snap. The battery cover stays on by friction. There are 2 cover files â€“ one for a 9V batt and one for 2-AAs. You will need: a high quality, hard plastic T-type battery snap with wires, a back-to-back 2 AA battery holder, an LED, a resistor, and a sub-miniature slide switch like (Jameson No. 621325).
- Install the battery snap. The snap will fit very snug so you will have to sand the ends of the snap a little to get it in. Even though it is very tight, I would still super glue it in place.
- Wire the switch. Keep all wires/leads as short as possible. Position the switch, tape it in place and drop a dab of hot glue on the back of the switch (inside the body).
- Install the LED. It also fits tight so use a round file to enlarge the hole just a tad. Put it in and super glue.
- Wire it. Cut the LED leads and solder the resistor, the ground and the hot wire from switch. I usually do it in that order.
- Push everything together, check for function (shorts) and then glue the top on.
Notes: My 8mm LEDs have a forward voltage of 3.2-3.4 volts at 25 MA but they still work on 2 AAs, theyâ€™re just not as bright. For a 9V batt and the 8mmâ€™s I use a 200 Ohm resistor. For 9V and a 5mm, use a 470 ohm. For 2-AA batts you can use a 10 Ohm or less for either size LED.