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LED Flashlight

by rstephen4048, published

LED Flashlight by rstephen4048 Feb 26, 2013

Description

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 – 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 – 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).

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Instructions

  1. 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.
  2. 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).
  3. 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.
  4. 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.
  5. 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, they’re just not as bright. For a 9V batt and the 8mm’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.
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