Mag-Light Tail Cap is Stuck. Ideas?

S

Scott Free

Joined
Sep 15, 1999
Messages
3,319
My mom-in-law asked me to replace the batteries in her D cell Mag-lite. She couldn't unscrew the tail cap. Neither can I. I've tried tapping it with screwdriver handle, running it under hot water, penetrating oil, and even a pipe wrench. I couldn't have put more muscle into the pipe wrench, but was beginning to really mess up the surface. I'm out of ideas. Any help before I take the wrench to it again.

(This seems like a good excuse to get her a nice LED for Christmas.)

Scott
 
I have a feeling that there might be some batteries in the tube that went bad and leaked, and "glued" the end cap on...Hose the battery cap down with some WD-40 and let it sit overnite...Then gently take the pipe wrench to it again. If it still won't come off, it's time to trash-can that one and buy her a Streamlight flashlight.
 
yep i agree with glockman, i have had that happen myself, ya might try a big wrench like he said, then spray the inside out with WD40(a bud said it would neutrilize the acid, ), i have had it happen 2 times, once the inside was wayy too corroded to try and salvage, the other one i sprayed out and its still working ok, the really bad one that i couldnt fix was in the trunk of my car, the batts REALLY leaked out bad, wonder if the heat caused it?

good luck!

greg
 
I had the same thing happen with a maglite and once I got it open (and determined the battery manufacturer) I shipped it off to the battery people and received a brand new replacement, fresh in the package. Most of the big battery people guarantee against damage from leakage. I've been working on a maglite for over a year (off and on) trying the penetrating oil/wrench bit every now and then (it's sitting on a towel spread on top of my clothes dryer) with no luck yet. Wish I could remember whose batteries are in it! I'd ship it unopened if I was sure!:D Good luck!



Larry S.
 
Word is Mag-light takes good care of their customers and will probably just replace it for free if you send it in. They can probably easily afford that, since probably about a million stockings will have a Mini Mag-Light stuff in them this (and every) Christmas. :D
 
I'm pretty sure that the battery leakage is not the problem as she was using the light just a few days ago.

I'll try the overnight with WD-40.

Thanks,

Scott
 
Rather than using a pipe wrench, why not use a strap wrench? I'll reduce the damage to the light.
 
Might take it apart from the front, you can't dump the batteries that way, but you could pour some oil down the inside
 
Are you sure it isn't because you're not strong enough?
Maybe you should send it over to one of the big boys on the forum to open it up for you? :) jk

I agree with trying to use a strap wrench. Something like the boa?
 
Point44 said:
Are you sure it isn't because you're not strong enough?
Click to expand...

Ouch!

I did try a strap wrench. The strap was made from rubber and eventually slipped or twisted. I was afraid I was going to break it. (I'm THAT strong!) :)

Maybe the strap wrench was a cheapy. Are there different grades of strap wrenches?

Scott
 
The mechanic in me says: Use heat. Expand the outer threads. It's aluminum and it expands quickly. Use propane carefully.

*IF* the WD40 fails...

Coop
 
the light i salvaged would light up(very dim)w/the bad batts in it, FWIW, it was a 5 cell/guess only 1or 2 leaked, the rest still had enough juice to light the bulb (barely)

i agree send it in for a new one if possible, am sure its hard on the switch/etc when they get that funky inside, wonder how long mine will work.....
 
My maglite(AA) done the same in Nepal in '91 I sent it back to Maglite they fixed the problem and sent it back to me. I paid shipping to US they paid shipping back to AUS. I found out from my friend somtime after when heard me talk about it he seen one of the sherpa's staying at the hostile playing with it one night and wondered why after that he never seen me use it again. Maglite told me it was crossthreded, but still fixed all the problems. ;) :D ;)
 
As Coop says, try heat. The Maglight "cap" is really a plug. Don't heat the cap, heat the tube just above the cap. Don't over-do the heat since the aluminum will get soft and sticky if it gets too warm. You also don't want to cook off the batteries. There is also a neoprene o-ring that will get damaged by too much heat.
 
Planterz said:
Word is Mag-light takes good care of their customers and will probably just replace it for free if you send it in. They can probably easily afford that, since probably about a million stockings will have a Mini Mag-Light stuff in them this (and every) Christmas. :D
Click to expand...

Yep, that's too bad, for about the same $, the Dorcy 1 AAA LED light is much better on batteries and is brighter, longer.

Ahh, the power of advertising.. How many years have we seen the Maglite commercials? Have the lights changed in 20 years? Nope, and neither has their reputation.

The Dorcy 1 Watt (3 AAA) is now at Target and would make a very compact and decent replacement for any 2 or 3 cell maglite. Not quite as much throw, but much smaller size.

If the stuck tailcap is that stuck, the insides of the tube are probably in very bad shape. If a vice and pipe wrench don't get it, it's time for a new one. Get a Dorcy (if it's for indoors) or a new Mag at Target as they are VERY much on sale the past week or so.
 
SharpByCoop said:
The mechanic in me says: Use heat. Expand the outer threads. It's aluminum and it expands quickly. Use propane carefully.

*IF* the WD40 fails...

Coop
Click to expand...


Use the blue wrench. Shouldn't take much heat to pop the sucker loose.
 
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