Alternatives to JB Weld?

Make a small lanyard out of kevlar or HD nylon thread, secure it to the light and with an inch of slack, secure it to hole in the top of the clip. Sure, the clip will still pop off on occasion but you won't lose it. If you permanantly glue the clip down, the next time you snag it on something you'll bend the clip and then you'll have a bent clip that won't work and that you can't get off the light.
 
You can't solder aluminum. You can weld it, but you can't solder it.
And before anybody even goes there, welding steel to aluminum is also a non-starter.
And before anybody even goes there, by the time the steel is sufficiently heated up, the aluminum is going to melt/deform.
Considering that both the clip and flashlight barrel are extremely thin, we're talking about very narrow margins of error in terms of not ruining the flashlight.
 
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Sharp Phil said:
Here's the promised picture:

laserdevicesclip.jpg
Click to expand...

If you could find a spring clamp the right size, you could fix that in less than a second with no modification other than cutting off the clamps protrusions. You might even be able to use a keyring if it would fit.
 
..i don't see why drilling/tapping will destroy the integrity of the tube..

..or just lick it and stick it. ..sniff it every once in awhile to see if its drying out.. ..then just lick it again..
 
A couple of twists of aircraft stainless safety wire would do it. A local machine shop might have a spool, if there's no small airports around.
 
if you try to JB weld the clip to the body, the tension of using and releasing the clip will eventually break the bond, especially since they are two different metals. BUT if you are willing (and this is a slight variation on the wire-tie idea) to wrap a piece of steel shim AROUND the round part of the clip -- so you have a sandwich of flashlight-clip-shim -- you could either JB Weld or solder the shim to the clip. Same metals, & no real tension between them to break the bond. If you use a hi-carbon shim it would be easy to blue or patina it dark, and it doesn't need to be thick at all. Hope that explanation makes sense?
 
for what it's worth, I find that the quickset JB Weld is not quite as good as the regular. get the original that cures slowly.

I second roughing the surface where the clip will mount. if you think you could drill a small hole without screwing up the internals, that would be better as long as you use a very small dab of JB Weld so as not to have enough ooze in to create a conflict with the battery fit.

some of the other suggestions here seem unwieldy to me. if done correctly JB Weld would not even be noticeable
 
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