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12/1/2011 7:35:01 PM EDT
Hello All,
Does anybody know of a way to convert a Surefire 960 weaponlight (3-battery) to a 2 battery light?  I changed the lamp to a P60 & removed the body adapter but there stll appears to be a slight gap that does not allow the battaries to make contact with the coils.  Any help is much appreciated!
Regards!
12/1/2011 8:12:22 PM EDT
[#1]
How much of a gap is there?  Use a filler, like an aluminum or copper slug/plug.

The key is to have a lamp that runs off the battery voltage you supply.
12/2/2011 12:36:46 AM EDT
[#2]


This is a Classic Weaponlight 960, right? When you say you removed the body adapter, do you mean the part that the tailcap screws onto when it uses 3 batteries? In the chart below, it's the A21 adapter, which screws onto the L90 housing. Is that how your 960 is? If so, the problem is likely at your tailcap-to-body connection, as the shortened threads of the L90 housing aren't meant to take a tailcap and probably do not reach the electrical contact in the tailcap to make a complete circuit. Compare the length of the threads of the adapter and the body housing, the threads on the adapter should be longer.



To be certain, take your complete body housing/lamp/bezel, place two batteries in it, and then take a piece of metal (nail, paperclip, butterknife, etc) and touch both the battery contact and the wall of the flashlight - you're completing the circuit without a switch. If it lights up, you now know that the problem is the switch/body connection. Unfortunately, there is no easy solution, as those shortened housing threads are not meant to take a tailcap, even though it may seem like it fits. You'd need to remove metal from the tailcap or the body housing (which isn't guaranteed to work), or replace your L90 body housing with the L60 housing (to use with your A21), or replace the body housing with a normal two-cell flashlight body.



12/2/2011 10:19:34 AM EDT
[#3]
That's right, the Classic 960 WeaponLight is based on the L90 Lamp Module and there is no easy way to convert the L90's Lamp Module Housing Body into the L60's Lamp Module Housing Body so that the WeaponLight only holds two SF123As.



There are several solutions:

1) Purchase a SureFire Z20 Battery Spacer so that you can use your three-SF123A WeaponLight with only two SF123As.

This is a discontinued item and it may be easier to find an aftermarket alternative.

2) Purchase a SureFire L60 Lamp Module. This is the only way you'll get an L60 Lamp Module Housing Body unless you find a person with this component for sale/trade.

3) Consider replacing the L90 with an LM2 LED Lamp Module.
12/2/2011 7:40:26 PM EDT
[#4]
Thanks for all of the info Gents!  I'll probably just keep it the way it is for a spare light considering the price to convert it...
12/3/2011 5:40:59 AM EDT
[#5]
There are some very good options for converting a 9V (three-SF123A) light from incandescent to LED.
For example, SureFire's KX4 LED bezel can be powered by either two or three SF123As.

Also, it's well worth contacting forum-supporting SureFire Dealers as they are a lot of experience in helping people convert from incandescent to LED and from Classic WeaponLights to current offerings. Buying from SureFire.com is the price you pay for not having a friendly SureFire Dealer to help you.
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