maglite

[Eve]

I got my gear out of the cryogenic deep-freeze it's been in the other day and found that I could not open it to change the batteries. I used pliers but just scraped off paint. Should I assume the batteries have corroded it shut and the light is a lost cause?

(Yes, the moral of the story is go caving more often!)

[erebus]

Why do you keep your gear in a deep freeze?

It's possible that the batteries leaked and corroded the aluminum threads, but there may be other things you can do. If you know anyone with access to a metalworking lathe, they could chuck the end cap in a collet and put a strap wrench on the body. Your problem with the pliers is you can't get a good enough grip. (And that's anodizing, not paint.)

If the maglight is toast (and it's a mini-maglight), I suggest replacing it with a Tasco one-Watt LED light. Similar form, but it burns much longer on a set of batteries, and is comparably bright. BJ's Wholesale has them two for $20.

[Eve]

That was a metaphoric deep freeze. As in, not having been used for a while.

[NZcaver]

Since you've scraped off some anodizing anyway, try this.

Tap around the cap end of the maglite with something solid (this may help to loosen the thread). Then use 2 pairs of pliers - or better still, vice grips - with one pair on the cap and the other on the body. If that still doesn't work, or you find the batteries are corroded beyond recognition, it's probably time to retire the flashlight.

[fuzzy-hair-man]

Careful clamping around the body as it will be easy to squash the tube that forms the body and you might get the cap off but the batteries will be hard to get out. Of course if you can't get the cap off or the batteries out it's broken anyway but...

[erebus]

I would not use Vise-Grips; the body of the flashlight is thin aluminum, and Vise-Grips can exert enough of a squeeze to crush it. Then the Maglight would definitely be junk.

[hewhocaves]

although the maglite sounds like it's toast, it might still be worth opening to scrounge for parts. you can always use spare mag-lite parts.

[Eve]

I don't have ready access to vice grips or a lathe, so I guess I'll try tapping and two pairs of pliers. Thanks for the suggestions.

[Scott McCrea]

Hi Eve. Welcome back!

In the FAQ section of the Maglite webpage (LINK, second one down) it says that if the tailcap is stuck it is most likely leaky batteries... blah, blah, blah... they will fix or replace it if, IF, they are name brand batteries.

Good luck!

[Eve]

Ha, that's a conundrum. I don't know if they're name-brand, and I can't check without getting it open, at which point I don't need their help ... ! But I'm cheap so they're probably Kroger batteries.

[potholer]

One thing that might be worth trying if nothing else works is briefly pouring some boiling water over the end, (or dunking the end in a pan of boiling water, and then immediately trying to unscrew the end with your grips/pliers - if the outside of the tube is hotter than the 'core' of the plug, it might expand the tube slightly and make it a less-tight fit.

Alternatively/additionally, to avoid crushing the tube, it might be possible to grip it with hands, by wrapping a sheet of rubber around it, or maybe use rubber (or a few rubber bands wrapped around the tube) to increase the grip of grips/pliers without heavy pressure.

[erebus]

As a variation on potholer's technique, set the light upright on an icecube (to keep the end-cap cold) while heating the body with a hair dryer. (Or freeze the end-cap with your cryogenic liquid of choice.) Do not use a torch or stove burner to apply heat; batteries can explode.

The principle behind heating one part while chilling the other is that metal expands when heated, and a hole in metal expands when the metal is heated, too. It can make a tight fit loose, if the inner part is cooler than the outer one.

You must do your unscrewing while a temperature difference exists. That won't be for very long with aluminum.

[NZcaver]

I would not use Vise-Grips; the body of the flashlight is thin aluminum, and Vise-Grips can exert enough of a squeeze to crush it. Then the Maglight would definitely be junk.

Not to split hairs, but the reason I suggested using vice grips is precisely because you can set them to lock at a particular grip size - therefore avoiding over-squeezing and crushing the poor Maglite to death. You don't have the same luxury with regular pliers, but if that's all you have - and you're careful - they should work OK. The tapping and/or heating/cooling will probably help too.

If the maglight is toast (and it's a mini-maglight), I suggest replacing it with a Tasco one-Watt LED light. Similar form, but it burns much longer on a set of batteries, and is comparably bright. BJ's Wholesale has them two for $20.

I'm not familiar with that Tasco light, and a quick web search didn't turn up anything either. Could you post a link?

[erebus]

Not to split hairs, but the reason I suggested using vice grips is precisely because you can set them to lock at a particular grip size - therefore avoiding over-squeezing and crushing the poor Maglite to death. :cry: You don't have the same luxury with regular pliers, but if that's all you have - and you're careful - they should work OK. The tapping and/or heating/cooling will probably help too.

My experience with V-Gs is that if you need to use them on something because regular pliers don't grip hard enough, and the something is crushable, V-Gs will crush it. They have to squeeze harder in order to grip better. Strap wrenches are a much better option.

I'm not familiar with that Tasco light, and a quick web search didn't turn up anything either. :? Could you post a link?

I wish I could. BJ's doesn't seem to have an online catalog, and nobody else seems to carry it. I did a Web hunt for it a while back and came up empty, but then BJ's started selling it again. It really is a good light, though.

[Scott McCrea]

I wish I could. BJ's doesn't seem to have an online catalog, and nobody else seems to carry it. I did a Web hunt for it a while back and came up empty, but then BJ's started selling it again. It really is a good light, though.

Are these them?