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1Add PCB mounts to the flashlight
I glued four M3x18 screws to the chassis using cheap epoxy. The unpopulated pcb served as a template. I carefully adjusted the position of the screws until the footprint of the LED was placed exactly above the hole in the reflector. I also carefully removed some of the reflective coating on the reflector that faced the inside of the lamp using fine sandpaper. It seemed to be conductive, so it is just a safety measure against shorting out the leads of the LED. -
2Modding the original internals
I wanted to continue using the original switch of the lamp. Therefore I soldered the wires from the battery pack and the PCB to the former battery and lamp holders. I had to shorten them quite a bit using a dremel to have enough space for the PCB.
(All the components are already in place because I took the photos after completion, sorry for that) -
3Solder components to the PCB
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4Connect everything
Now it is time to connect everything. It would also be a good idea to use some velcro for affixing the battery pack to the back of the lamp.
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