DIY FLASHLIGHT - Radio Shack

Example 1
7 Insert the soldered components (the assembly) into
the pipe, and insert the switch through the rectangular
opening. Center the LED in the pipe and note where the
resistor contacts the inside screw.
8 Remove the assembly from the pipe, and bend the
resistor lead so that it will hook clockwise (with the
thread direction) around the inside screw.
9 Insert the assembly into the pipe; insert the switch
through the rectangular opening, and then hook the
resistor lead around the inside screw.
10 Using the switch mount screws, secure the switch
housing to the pipe. On the inside screw, tighten the
top nut to clamp the resistor lead securely.
11 Use a 3-inch piece of electrical tape to insulate and
secure the desoldering braid to the inside of the pipe.
Instructions
1 Cut a 4 1 /4-inch long piece of PVC pipe (1-inch
diameter). Sand and clean the ends.
2 Measure 1 /4 inch from one end of the pipe and drill
a 5 /64-inch hole. This hole represents the front mount
of the switch housing. Using the switch housing as a
template, drill a hole for the back mount of the switch
housing and a rectangular opening for the switch itself.
Be sure to make the rectangular opening long enough
to move the switch on and off. (See Example 1 image.)
3 On the opposite side of the tube, measure 1 1 /4
inches from the front end and drill a 3 /32-inch hole. Insert
the 2-56 screw through this hole and secure with a nut.
4 Cut a 5 1 /4-inch long strip of desoldering braid. Tin
one end of the braid (apply a small amount of solder) so
that you can form the end into a hook to make soldering
easier. Solder the braid to the center post of the switch
housing so that it extends to the back of the pipe.
5 Solder the negative (short) lead of the LED to the
front post of the switch housing.
6 Trim the positive (long) lead of the LED to 1 /2 inch, and
trim one of the resistor leads to 1 /2 inch. Solder the trimmed
resistor lead to the positive lead of the LED.
12 Insert both batteries with the positive terminals
facing the front of the pipe; the back end of the
second battery may extend outside the pipe. Trim
the desoldering braid so that its end aligns with the
battery’s negative terminal.
13 Apply a small amount of solder to the end of the
desoldering braid. Wrap the braid in electrical tape,
leaving the end with solder exposed.
14 Cut a 3 /4-inch piece of foam tape, remove the
adhesive covering from only one side, and attach
it inside one of the PVC caps. Place the cap firmly
over the battery so that it holds the desoldering braid
against the battery’s negative terminal. Slide the switch
on to test the flashlight. (The LED should light. If it does
not, check all the connections and ensure the battery
terminals are making contact with both the inside screw
and the desoldering braid. Also, make sure the switch
opening is wide enough for the switch to slide fully.)
15 Drill a 5 /8-inch hole in the center of the remaining PVC
cap so that the hole aligns with the LED.
16 Rotate the cap so that the open end faces away
from the LED. Thread the LED through the hole in the
cap. Use hot glue to secure the cap to the pipe.
Step 7
Steps 4 & 5
Step 6
For more detail, including project schematic,
go to www.radioshack.com/DIY.
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Parental supervision is strongly recommended when using power tools and solder. Always wear safety glasses. Avoid breathing fumes and always work in a well-ventilated area. Wash hands
thoroughly after use. Follow all safety instructions on solder and soldering equipment packaging. California residents: WARNING: Soldering products contain, or when used for soldering and
similar applications produce, chemicals known to the state of California to cause cancer and birth defects (or other reproductive harm).