REDESIGN PROJECT-MAGNALITE RL85
Recently I was asked to redesign a Magnalite RL85. This light is a handheld 100 watt unit with red reflector lens and is turned on by an on-off switch located in the handle. It uses an internal 18650 Li-Ion battery pack with an internal circuit board for recharging. This light was not lasting long on stand because it was always full-on and battery life was only about 50 minutes.
The client wanted me to install a dimmer, and provide for external recharging. He also wanted to be able to switch battery packs in the field, as in the original design, once the batteries were dead, you had to take the light out of the field and plug it in to recharge, thus no more hunting till the batteries were at full charge once again.
I began by dissembling the light, and removing the battery pack. After careful study, the circuit board was removed and placed into a small sturdy housing with wiring access for the battery pack and plug-in wall charger. I then manufactured a dimmer circuit and placed it into the light where the batteries had previously been located, wiring the light to the dimmer and extending the wiring and new battery connector from the bottom of the handle.
The client sent me a new battery pack, and I attached extended wiring and power connectors to both packs, carefully preserving the original charging connectors as well. Since the battery packs were not symmetrical, I hot glued dowel rods to make up a symmetrical pack, and wrapped them with special flexible vinyl electrical tape.
Now the client can place the battery pack in his hunting jacket to keep them warm, and by utilizing the dimmer can preserve battery power at the same time. When one battery pack is exhausted, the client simply attaches the new pack and continues his predator hunting.
