Key West Sunrise Flashlight–a AAA lightweight

Key West Sunrise will be a flashlight made from Italian plastic normally used for making pens. It is very light, and this particular mixture is very bright, too, hence the name Key West Sunrise.

But, as we know, plastic does not conduct electricity, so that meant a flashlight within the flashlight body would be needed–in this light it is being made from 7075 Aluminum. I was successful in installing the metal sleeve to the head, and in the photo below, you can see the battery tube has been drilled and the inner metal sleeve has been machined. Next step is to press fit the metal sleeve into the plastic battery tube.


I wasn’t 100% suyre how much leeway to allow for the press fit, but since the sleeve fit fine in the head, I opted to use that tolerance for the battery tube and its metal sleeve. Imagine my surprise about a minute later, after the sleeve had been press fit into the battery tube, when I heard a crack and saw the battery tube sitting on the floor. Uh, oh!


Yes, the fit was either too tight, or I had compressed the air so much, as there was no way for it to escape, other than by breaking the plastic. I’m not exactly sure what was the culprit, but when I re-did the plastic battery tube, I cut the opening a few hundredths of a millimeter larger, and provided an escape path for the air by scratching some v-grooves in the metal sleeve as well. And, whatever it was that mattered, it worked:


This is an amazingly light light (no pun intended), partly because it uses a 10440 Lithium-ion battery, but mainly due to the light weights of the plastic and aluminum.

I plan to install a miniFluPIC three-level driver and a Cyan LED.



Here’s a close-up of the completed light, showing the two metal components within the light:

Key West Final-5


And the final completed light:

Key West Final-1


Key West Final-3


The light has been sold.

If you would like to be on my Lights for Sale Opt-in List, please send me a note and I will add you to the list, so that you will receive any future offerings of my spec builds.

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