Maglite Flashlight Batteries Stuck Removal Guide / How to Remove Exploded Batteries

Maglite Flashlight How to remove stuck batteries or exploded batteries from inside a Maglite. How to save your Maglite from the Trash. If your batteries have become corroded and swelled up inside of a Maglite don't throw it away, I show you how to remove them and restore your flashlight to a working condition with minimal effort.
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[@ModernDIYProjects]

In this video I explain how to prevent batteries from exploding inside your Maglite and possibly ruining it, and if the batteries do explode or leak and swell up, how to get them out without damaging or ruining your Maglite. I also throw in a few useful nuggets of information along the way. Hope you enjoy the video!

[@ozdavemcgee2079]

Yeah. The new ones are nowhere near the thickness of tunmbe as the old ones

[@ozdavemcgee2079]

Btw, which way, looking face onto bulb, does that part unscrew?? Yep got a bettery stuck corroded lol

[@ModernDIYProjects]

@@ozdavemcgee2079 Keeping in mind that mine is a 30 year old design and newer ones may be different, it's the standard lefty loosy. It is common for that part to get stuck, so don't force it or you could break it. Do what I did and soak the batteries until you can get them to loosen. Also, you can get a really long lag bolt, drill the batteries then screw the bolt into the batteries and and pry them out from the other end.

[@arnarne]

My batteries are stuck.... Can i really pour a solution of baking soda and water into the tube without damaging the torch?! Thank you v. much for the video!

[@ModernDIYProjects]

Yes you can. It wont harm the aluminum body and it will neutralize any acid in there. I may fizz like crazy so just be ready for that.

[@203001993]

I can't believe it! Your idea of pouring oil into a Maglite actually worked on my 3-cell. I unscrewed both the top and bottom parts and set them aside. I used a vise to hold the Maglite upright (bottom up) and put a small catch pan under it. I opened a can of regular motor oil and filled the flashlight up to the brim. For several days I added oil every time I walked by (just like you said). The oil ran down along the batteries, past the switch, and through the top of the flashlight and dripped into the pan. After 2 or 3 ounces of oil ran through I decided to see if I was doing any good so I took Maglite out of the vise and whacked it down on a 2x6 on the garage floor. After a few hard hits I noticed the battery had moved a little. A few more whacks and whatdoyaknow, the bottom battery came out. I kept going and the middle battery and then the top battery came out too. The MagIite's threads were not damaged. I used a screwdriver and a file to dig off the corrosion caused by the battery. I sprayed brake cleaner and contact cleaner both into the flashlight to clean up the mess, using a rag and long screwdriver to swab everything out. I actually put a little lithium grease on the batteries before I put them back in. The great news is the Maglite works! Hope you're able to get yours going again too. One last comment; I threw a 2-cell Maglite away last year that had corroded batteries. I tried the lag screw method to remove the batteries but it didn't work for me. They were stuck tight. It did hurt to toss it in the trash. I wish I'd tried the oil soaking trick with it. :-)

[@ModernDIYProjects]

Another Maglite avoids the trash can. Glad to hear that! 👍

[@f50koenigg]

Did you have the 3rd gen maglite?

[@onpsxmember]

All you have to use to neutralize the alkaline crystals is citric acid you may use to get rid of scale in your water boiler.

[@TheReal1953]

I think there is better way than oil. NAPA has a corrosion battery cleaner that would be more suited. As onpsxmember said, you need something to neutralize the alkaline crystals.

[@skeptic3332]

It's garbage day today and walking home from the store I spotted the exact same one laying on top of the garbage. When I got home and opened it yeah what a mess. So I google Maglight batteries exploded and voila I'm here. Thanks after a few hours I got them out. The flashlight looks brand new. I suspect they never used it and well decades old batteries will do what they do. Thank you.

[@PanamaSticks]

I'm 65 years old. When I was a kid, batteries leaked. The battery manufacturers would GIVE you a new replacement flashlight, radio, etc. They got tired of doing this and started making batteries that didn't ever leak. They were leak free for years until the manufacturing went to China. Now they leak again. And I have had a $175 GPS unit destroyed by leaking batteries. (There are so many screws to take the battery cover off, I didn't check as often as I should.) The point is, WHY DO PEOPLE ACCEPT THIS? IT is NOT the flashlight that is at fault. IT IS THE BATTERIES. COMPLAIN to Eveready, Duracell, Rayovac, etc. THEY ALL LEAK. COMPLAIN. Maybe if enough people complain they will FIX the problem.

[@onpsxmember]

Yes the old batteries didn't leak. The reason why you don't have those anymore is the way they were made. They were heavy metals in there and amalgam that is sometimes still used to fill teeth in some places while mostly forbidden in the west. So if you don't care about anything and want far less power from them, then you want those. If you want to reduce the chances of leaking: Zinc-Coal, leak a lot cause the electrolyte is eating through the outer shell until it leaks out. Alkali-Manganese batteries leak far less (IF not the cheapest and if the whole thing can breath 1-1.5 years are fine). If they leak they'll leak from the negative pole (kathode) there are small holes to not have the battery really blow up from pressure build up. I still think they leak too often. Lithium based batteries can be stored for 10 years and have the best quality control so they'll have the least chance of leaking. In the 8th year or so it's still 90%-ish like when it's new and they can stand the cold the best too. So buy once, cry once. After the battery choice there are a few things to avoid to not increase the risk: 1. Do not mix somewhat used batteries with a new one if you got one left. Higher leakage chance of the old one. 2. If you know you won't use something for months and it's no emergency equipment, take them out. Some say to tape the contacts but giving the spring contacts some time to relax isn't bad either. Little bag with a clip or zip log bag with it. I do that for some measuring equipment I rarely use. 3. If batteries already leaked and it's some equipment you really care for, take the time to clean those (hopefully quality chromed) contacts with lighter fluid, alcohole (no extreme percentage for plastic) or what also works well is citrus acid (powdered to clean water kettle/water boiler and afterward some of the above to remove residuals of the acid. This milder acid (low concentration in the powder form with water) will neutralize and dissolve the alkaline crystals. Only if the contacts are clean they can't help to corrode the contacts and corrode the batteries' contacts when they are left there. It has to be spotless. if you read this far I recommend the Bunny in the max variant. If some is left, it'll eat at the spring contacts and they'll snap off. Luckily those are mass produced and cheaply found online. 4. In worst cases, you can use sand paper or a glass fibre pen that is used to clean circuit boards. That takes off material from the contact and from that point it will corrode far more than with the chrome on it. So don't use abrasives unless you see no other way and it just has to work for now.

[@fibsone]

I swear to god I don’t remember that being that big of an issue either. In more recent years it’s like they all do. Past couple months I was doing my rounds changing batteries and at least half had bad batteries.

[@fibsone]

“Chy-Na”

[@ralfbaechle]

In my experience alkaline batteries will leak. Period. Leak-proof is just advertisement.

[@hovanti]

Thanks for the video; I used several tips you mentioned, including baking soda and oil to save my 3D cell Maglite. Fortunately, only the rear most battery leaked, so the slight corrosion damage inside the tube was easy to get to in order to clean it up and smooth it out. That corrosion, however, did make me fight to extract the one leaking battery, so I ran a screw into it, locked Vise Grips onto the screw, then tied the pliers to an immovable object with a short piece of stout rope and gave it a mighty yank-success! The other two batteries slid out with little effort, so overall, I was pretty lucky. Irks me though, how batteries surprise you like this; I have another Maglite with store brand batteries with a "Use by" date of 12/2009! Just checked it, and all is fine. Some years ago, however, I discarded a like-new 2D Maglite because the batteries ruined it within the first year.

[@fakiirification]

there is a lock ring in front of the switch assembly, and it is held in with a set screw under the rubber button. it can only slide out backwards like the batteries.

[@Andihollywood71]

This is amazing!! I used the oil trick and it did the trick overnight! Thank you!

[@bryancunningham1095]

Great video, the electrolyte in these batteries is potassium hydroxide and is very hygroscopic (draws water from the air) this is the biggest reason they swell up and there is also outgasing going on in this sealed tube environment, if someone else commented this sorry, i havent read all the comments. Great video to learn about the Maglite construction.

[@vincentrichardson1972]

Thank you, thank you, thanks you! The Duracell batteries are a tight fit at the best of times but when they explode then you have a serious problem. The oil treatment, large scewdriver to turn the battery and a coach bolt into the battery to pull it out eventually worked for me. THANK YOU! Perhaps I should point out that this is my emergency torch (doesn't get used much) and the expiry date on the battery was 2010. Respect to Duracell because the spare batteries I have are all 2010 and all have retained their full charge. Only dropping the torch on the garage floor led to this discovery, suspect a slight airgap as everything worked when I put it all back together.

[@albear972]

Thank you so much Sir! You saved my old trusty 4 D cell Maglite that I bought new in December of 1993 upgraded to the LED bulb. Danged Duracell! The 4 of them got stuck in the flashlight and I couldn't get them out. I tried the oil trick and it leaked through. I recirculated the oil about 10 times then banged the bottom on a piece of wood. The batteries got dislodged with the oil and the banging. Even banging the bottom of the Maglite it didn't cause any damage at all! And I'm skipping buying Duracell batteries from now on and maybe stick with zinc carbon type batteries. I have a feeling that those won't cause any future drama.

[@Tawanix]

Wow, thank you for the video! I bought a used vehicle and they left a few things in there, a Mag-lite was one of them (Such an awesome find!). The very first battery is stuck and it's somewhat hard to get to. I'm going to try the oil you suggested.

[@tamiz8895]

I’m gonna try this! I bought a Maglite, I think it’s a 3 battery model, from a thrift shop -I love these lights, they are the best! I thought I’d make the small gamble, considering that the price was $4. I could not get the back cover off so I took it over to my husband’s bench vise and it worked! But the batteries, however old they are -are fused inside! ☹️ I can’t get the bulb cover part out so I’m just leaving some 3-in-1 oil in it to try my luck 🍀 THANK YOU so much for posting this…I really want to make this oldie work again!

[@ElectronicsNotes]

Thanks for the video - the most comprehensive one around. It unlocked the final step I needed to remove a leaky battery that was well and truly jammed in. Yours was the only video that showed me the final step I needed. Thank you so much.

[@slodown3670]

A really excellent and clear description of how to disassemble and fix a Maglite 6 battery cell torch (flashlight)!

[@lupillos7404]

The way I did mines I drilled a screw on the first battery pulled it out with vise grip pliers was little hard but got it out then I put hot water from kitchen sink let it running for 5 minutes in battery tube and used a butter knife to wiggle the other batteries took little time then finally rest batteries came out now inside tube was dirty of battery acid so I let more hot water used soap put a bottle scrubber inside tube clean as good as I can then with a air compressor dry inside tube really good then put back together and greased it good and put new rechargeable batteries instead of regular alkaline batteries and my Maglite was back working for people that have old Maglite flashlights don't throw them away I was about to thank god I didn't New Maglite flashlights not made the same old school better build to last and last long time.

[@silkeless1235]

Worked perfectly well with my Mini Maglite, thanks a lot. Highly appreciated.

[@ModernDIYProjects]

You're welcome!

[@GenevieveThornton]

Omg thank you so much!!! This worked! I went through so many of these stuck maglite battery vids and thought I’d have to drill a hole or just toss it because they were soooo stuck. Yours worked! Thank you!

[@KJ-gc8oq]

I want to thank you so much for yr video, i refused to give up but was at my wits end. I tentatively used yr oil advice, and it worked, IT WORKED. Im beyond happy, amazing! You are a genius 🤗

[@wonderbill8188]

Thanks for this. I have the 3-AA cell Maglite w/a stuck top cell. Started with baking soda and water, then hot boiling water, then WD40, the latter requiring several appls, patience, and poking. Finally freed up and saved me from trashing it and spending $$$ on new....

[@MusicLaLam]

Wonder Bill Thanks - great tip. WD-40 worked for me too - just a couple of appls and freed the very corroded batteries in minutes.

[@simonsignolet5632]

I've been watching a few KZbin vids on this matter: my 40+ year 3D cell Maglite (genuine) has a different locking mechanism for retaining the bulb/switch assembly. It has an external thread locking ring instead of a spling clip and it needs to be unscrewed using a two pin type of spanner. I'll have to make one. The locking ring slides out FRONTWARDS and, I imagine, so too, does the bulb/switch assembly. Thanks for this video, especially the explanation of how the battery gases react with the aluminium case, causing expansion and leakage. Once I've removed the offending stuck battery, cleaned out my tool and regreased (with ATF) the threads, I shall store the torch with the batteries outside of it and next to it.

[@sergest-amand1164]

Ty for this video. I have a mini maglite (2xAA). I also had a "ultra mini" maglite (1xAAA). I had an expanded battery in this one. I found good advice here:). Mine was in really bad shape though. After several cumulative hours of work, still unsuccessfull, I had to put a screw in it, then pull with a tool. Only the heart came out. Then scrubbing out the black "powder", then trying to dislodge the outer "welded" "skin" of the battery while prying with the thinnest flat scrwdrvr i could find... I stopped there cuz anyway during my 1st tests I damaged the plastic part near the bulb, and also I didn't have the many other hours needed to eventually finally succeed... I'll sure apply your suggestion to open the surviving one once-a-month to let it breathe! Tkx for the explainations also about these phenomenons, your video is the only one I found on Yt on this subject that was explaining the causes! I also like your vids on some of your old tools since my father had the same and he gave those to me:).

[@ModernDIYProjects]

Thanks for your comment and I'm glad you enjoy the tools videos that I show. I didn't mention in the video to use a screw to pull out the batteries because I didn't want someone to get hurt with the battery exploding, or the chemicals inside etc, but you obviously were smart enough to know how to protect yourself when doing that. Glad I could help!

[@sergest-amand1164]

@@ModernDIYProjects The videos I saw about this "method" were not talking about a possibility of explosion or leak, if you can tell me more i would appreciate. Was wearing gloves, mask, goggles and kept head away cuz i tend to be cautious though!

[@ModernDIYProjects]

@@sergest-amand1164 I didn't mean exploding like a bomb, more like just toxic chemicals coming out and possibly hurting someone who is not careful. You did it the right way. I always try to be extra careful when I mention things on video because if there is a way to get hurt, someone will find it and then could possibly blame me for their mistake. It's a minor danger, nothing great, so not to worry.

[@72andres]

Awesome advise. Thank you and God bless!

[@sherirocco7726]

About a half teaspoon of white vinegar did the trick perfectly! Thank you!

[@robertbrunston5406]

Very good! Thank you.

[@gregnissen3950]

Good information....thanks!

[@alfonsosanchez7377]

GRACIAS, MUY BUENA EXPLICACIÓN, YO TENGO UNA DE 3 CELDAS, INTENTARÉ REVIVIRLA. :)

[@southernsandra]

My blue Maglite still works well.ive had it 30 plus yrs

[@bertuchi1990]

ABSOLUTELY FANTASTIC, LOVE YOUR FLASHLIGHT. I HAVE OWNED ALL THE MAGLITE MODELS SINCE THEY ARRIVED IN SPAIN IN THE 1980S. I HAVE A LARGE AMOUNT OF LAMPS OF ALL VOLTAGES, XENON, KRIPTON, HALOGEN...ETC. EXCELLENT VIDEO. GREETINGS FROM A FRIEND FROM SPAIN PASSIONATE ABOUT FLASHLIGHTS.

[@ModernDIYProjects]

Bienvenido. Glad you enjoyed the video. Best of luck with your collection.

[@AntipodianMusic]

I still have the same one I bought in 1989.

[@richardgomd]

Buy from maglite directly... they still sell the 6D incandescent for $28 and 5D cell incandescent for $25

[@firstchristianchurchatchis3768]

Replace the bulb with a LED replacement bulb and you’ll be amazed at how much brighter the flashlight is.

[@createdforel2486]

Don't try to "unscrew" the bulb carrier/switch assembly. That will break the assembly! The assembly is held in place by a snap ring which sits on a groove on the front end of the flashlight as a stop and a set screw. The normal way to get the assembly out is by removing the rubber cap on the on/off switch and then accessing an allen head screw that is the set screw. There are youtube videos that explain how to do this. If it is possible, you can undo the set screw then try to remove the snap ring to access the front end of the tube. If you can do that, then you can try to whack the battery from either end.

[@motanel]

I'll try today and see 👀 Thanks 👍

[@xsmatt81]

i don't have a big boy 6D, just an old 4D mag, i had left for a few years under seat in mustang. Regular rayovac D's in it. So being well in Las Vegas in 110+ temps in summer, and at times below freezing in winter, of course it ruined it. I forgot it was there. Took a couple days, but got the suckers out. At first just banged it on carpet/floor, one came out fairly easily. But the other 3 corroded/bulged in tube...Let baking soda/water soak an hour, and banged on it more. Another came out. But that wasn't fast enough, decided to just spray good ole WD40 in it, let it sit a while. Boom, with some more banging , came out. Then just went to town with baking/soda water and a long fish tank brush/rags and got the corrosion out of tube/contact, cleaning up the threads on screw parts, lubed the o rings with dielectric grease. good as new with fresh cells the tip at start of taking the cap off on occassion is a good idea. But now i just keep this maglite in the house in a normal temp. In car i keep a LED with lithium battiers haven't had much issue

[@ChrisPalmer2000]

vinegar + oil worked for me! thanks!!

[@simonsignolet5632]

Works well in salad, too. 😃 Just don't recycle the "vinegarette" in your salad, afterwards! 😉

[@jangrewe]

It's called a momentary (and click) switch. Using citric acid is also very effective.

[@WeaselJuice]

Tried banging, then vinegar. Nope. Then I used WD-40. Allowed to sit overnight. A little tappy-tap and the battery came right out. I figured I’d grease all the seals while I was in there. Good as new!

[@WeaselJuice]

BTW, the plastic part of the flashlight near the bulb is held in place with a snap ring. It’s never coming out.

[@ModernDIYProjects]

Yeah, I could never get it to budge no matter what some folks have said over the years.

[@ModernDIYProjects]

WD-40 is a really great product no matter how much people love to hate on it.

[@DMACHOLMAN]

Thank you.

[@semco72057]

I have some Maglites and like them and have had some for over 10 years and the problem with them is the batteries which is a problem and stick in the barrel. Right now I have about 4 of them that way and will try once more to take the light apart where I can get the batteries out and clean up the inside of the light. I found that Ray-O-Vac batteries are the worst batteries to put in your lights and I use good batteries like Duracell in my lights now.

[@jefffoutz4024]

I've had every name brand battery explode at one time or another........

[@summereggleston4556]

I used a kitchen wood spoon and a rubber mallet to push the batteries thru

[@RyanK-100]

40 years ago it was rare that a battery would leak. Now I find that over half will leak - either a little or a LOT. I had two unopened packs of Duracell batteries (AA and AAA) with 32 - 40 batteries in each. See thru plastic packaging on cardboard. They were 4 years old and were stored in my guest bedroom away from light or heat. 4 out of 5 batteries IN BOTH PACKS were leaking and there was a white mess inside both packages. Duracell did send me coupons as replacements. But there must be a better way - the batteries destroy the device!

[@ModernDIYProjects]

I agree. Almost every device I open these days the batteries have exploded. It is either poor quality products being produced or ridiculous government regulations causing the products to be less reliable than what they used to be.

[@TravisNewton1979]

I just took my maglite and tap the bottom of the aluminum casing against a 2x4 until the broke loose

[@ModernDIYProjects]

But when they really swell up inside that just wont work. That is when you do a lot of cursing to the battery gods! 🤬

[@KowboyUSA]

A switch that doesn't lock or unlock when pressed is called a momentary switch. I quit using those Rayovac batteries in my Maglite's because they're guaranteed to leak and explode. It's unfortunate since you can usually get a dozen Rayovac batteries for the same price as a couple Duracells.

[@r80m]

White vinegar and a flat head screwdriver worked for me

[@leebird4690]

I got the battery out what do I need to clean my mag light with and what kind of pant do I use. Bleach got it out

[@ModernDIYProjects]

All you need to do now it clean off all residue from the chemicles you used. Rinse with soap and water. Allow to dry, and you have a brand new maglite to enjoy. It's that simple.

[@MrSaokid4463]

i have a maglite but the bottom cap is completely impenetrable. How do you get it to unscrew?

[@ModernDIYProjects]

If it is stuck because of age or rust build up I suggest you soak it in WD-40 or a rust/calcium removing solution. Soak it for a few days and keep trying to open it until it breaks loose. You can also take off the front cap and bulb and pour these solutions inside it to work from the inside as well.

[@MrSaokid4463]

@@ModernDIYProjects it not rust, the batteries habe exploded or leaked out inside and the bottom screw is covered with white subtance. Ill try the front, hope i dont break anything.😬 but thanks. Ill use WD-40.

[@ModernDIYProjects]

@@MrSaokid4463 Ok, now I understand. In that case try vinegar first. It will neutralize and disolve the battery acid which is what leaked out and causing the white stuff you see. Rinse and repeat a few times.

[@bruceberry1363]

I have a five cell and a four cell maglight,my favorite ! I replace the batteries so often I have never had a problem with battery corrosion. But it's nice to know what to do if it happens!

[@adriangargurevich2301]

@Sma 556 you should make a video explaining this.

[@teatonaz]

Sma 556

[@TheoneStanband]

What if the lid to the batteries is stuck? I have two mag lights with that problem.

[@ModernDIYProjects]

These bodies are aluminum. It could be battery acid corrosion or just aluminum oxidation (similar to rust but not) building up inside. Try soaking the battery cap part in vinegar and see if that loosens it up. Could also try 100% Lemon juice. That can help at times.

[@TheoneStanband]

@@ModernDIYProjects thanks dude, I'm gonna loose my sanity trying to fix these damn flash lights. Helpful advice is something I dont get enough of in my life.

[@usa_kenyan]

Where do you go to get a replacement LED bulb for the Maglite flashlight? I have an identical flashlight.

[@ModernDIYProjects]

There are several vendors that sell them on Amazon. Just look up the bulb number or model of your flashlight and replacement LED bulbs will come up on the search.

[@stuestrade7494]

Any specific weight oil that you recommend? Thanks

[@ModernDIYProjects]

It doesn't really matter. You are just trying to get something between the batteries to separate it from the body so any weight will do. You can even use cooking oil if you don't want to use a motor oil.

[@jacobperez8921]

My mini maglite flashlight cap unfortunately got stuck. What do you guys recommend I do?

[@ModernDIYProjects]

Just drown the cap portion in baking soda solution if you think the batteries have exploded inside. Then try oil to lubricate it and get it free.

[@jacobperez8921]

@@ModernDIYProjects ok thanks for the tip!

[@schumispecial1]

I am also in the middle of this problem. The plastic base structure at the bulb end does not have threads but a circlip. Very, very tricky to get loose. It is unclear what comes next after succeeding to take of this piece, as there is also the switch and its rubber. I will rather try to soak it internally with wd40 and do some tapping.

[@MartiBagwell]

I have 2 that are that way. If maglite’s so proud of their flashlights they need to do better. At 74 and a weak old woman I need my flashlights to work, that’s why I thought I’d bought the best

[@charleskuss8538]

Excellent tips for getting seized batteries out. At 12:10 you mention a brush to clean the tube. You can't remember the name of the brush. Do you really think an amateur is going to know the name?? It's called a bottle brush. It has nylon [or similar plastic] bristles. Better to obtain a bottle brush that has metal [brass or stainless steel] bristles. That will clean much more efficiently, with less work.

[@ceciljowers3795]

I have found that when I replace standard bulbs with led replacements they work great but will give good light even when the batteries get weak to the point of leaking. Would not have happened with a standard bulb because the light output would have been reduced to the point you would replace the batteries for a weak beam.

[@MrRockydee07]

Can we possibly use penatrating oil, the same stuff used to get rusted nuts from bolts .

[@ModernDIYProjects]

Sure you can. Anything that is slippery will work.

[@uldisbuks8845]

Can you rub silicone on the battery casings and gently slide in the batteries? Thanks for this great instructional video. Long Live Mag Lite

[@ModernDIYProjects]

Sure you can. Any long lasting lubricant will help.

[@tomhail3675]

What caused all the scratches inside? I thought the oil allowed the batteries to slide out.

[@ModernDIYProjects]

The oil does help, but when they swell up and practically weld themselves with the aluminumn body, it takes a lot of pushing and prodding to get them to move (ie. the scratches). If I could have opened both ends it would have been smoother, but my bulb did not want to come out.

[@engineerwv]

Wonder if you can use automotive battery post cleaner to help get them out

[@ModernDIYProjects]

Possibly.

[@shythawks9549]

Mine is legit sealed lol. I twisted the mag lights frame and I let it soak in some powerful shit to seep into the cap

[@simonsignolet5632]

How do you make "powerful sh*t" - eat a load of jalepeno peppers? You surely must have good aim to get it to go straight into the barrel - and surely someone has to hold the torch as you squat and squeeze one out... 😉 I think I shall skip this technique: I have close friends - but none that close!

[@kingofoblivion1822]

The oil doesn’t hurt or damage the flashlight?

[@ModernDIYProjects]

Not at all. Oil is a natural product so it wont damage aluminum.

[@dk6419]

I cannot get the battery cap off the back is there a way to do that??

[@ModernDIYProjects]

The cap is probably stuck due to battery acid leaking out. Try soaking the bottom of the light in some vinegar and try opening the lense and pousing vinegar in that way. Soak, Agitate then Rinse and repeat until you break the acid bond and it should open up.

[@markconger8049]

If all else fails, soak the entire light in oil for a week. Then pull it out and clean all the oil off. May need to use brake cleaner. Then put the light in a benchtop vise so the light is parallel to the ground (i.e. horizontal) and the stuck end is extending out far enough to get a big wrench on it. A pipe wrench with teeth will do. Adjust wrench to snug fit on the stuck end and give it all you got. Just rememeber to turn left to loosen! The end and body may have scars from the wrench and vise but ...

[@TheHyperAssassin]

What is the name of the part mentioned at 11:30? Or the part number? Mine broke, so I’m going to have to order one. Thanks in advance.

[@ModernDIYProjects]

That is the bulb mount. Can't give you a part number because it is probably different for each model. Look up your model number with Maglite and it should tell you what to order.

[@TheHyperAssassin]

Modern DIY Projects Thank you very much! :)

[@BKBK82228]

You should grease up the threads on the end cap and the head

[@dodgeramsport01]

why

[@BrianThorstad]

Well, my end is frozen. I have not been able to open it. On the light end, I see battery crud leaking. Sigh

[@kimchee94112]

My end cap was welded shut with the corrosion. No way to screw it out without destroying it. Yeah I say its water proved, soaking in penetration oil for a month does nothing, including using propane torch.

[@ModernDIYProjects]

Aluminum has a bad habit of welding itself together like that. It's just like rust on Steel. I would say to drill a small hole on the side of the barrel and see if getting penetrating oil inside of it will help. Also try soaking in baking soda and vinegar (separately, not together). Those can be rather helpful at times. The small hole on the body will not prevent future use if you get the flashlight fixed up.

[@amydelisead]

What can I do to get the cover to unscrew. I can't get my cover off

[@ModernDIYProjects]

Try soaking it in vinegar or a penetrating fluid.

[@jscottbell227]

I have a four D Cell battery with the two closest to the bulb REALLY welded in there. Using the long screw on the third battery after multiple lengthy oil soaks followed by some vinegar and backing soda merely pulled out a flat disc layer of metal from the third battery. Lots of more vinegar soaks and that third battery is pretty much hollow inside but the casing remains welded to the inside of the tube. Don’t have a course threading screw that can get close to the last battery. I also tried filling it with water and freezing it over a long week end since the water would expand as it froze. No joy after defrosting. I tried getting that C snap ring out from the front and broke off the tip of a curved rasp.😮 If I had some explosives I would blow the thing up just to get some satisfaction😔 Grr.

[@ModernDIYProjects]

Extremely frustrating I know. What you can do on that 3rd battery (since it is hollowed out now) is to use a long screwdriver and just pry it away from the flashlight body to push it in on itself. That will make it easier to pry out of there. You will scratch up all the inside of the tube just like I did, but at least you will save your light. The last battery you will need to find a long screw to reach it. Don't give up, you can do it!!!

[@jscottbell227]

@@ModernDIYProjects Sounds like a good plan however I am going to need to buy a longer screw just for this purpose. Used the longest one I had on the third battery and only reached around 1/4” into the third one.

[@bl3rry]

What kind of oil did you use

[@ModernDIYProjects]

I used motor oil but ANY oil will do, including cooking oil is that is more easily accesible.

[@fibsone]

I’ve had 2 Big maglites and 2 AA sitting in a box under my workbench for a good 5 years at least. I gave up trying and just bought better torches. I think I hung onto them with this weird determination in the back of my mind that I’ll get the batteries out one day. i could really care less about the lights cuz they’re a good 20yrs old and tech has advanced so much those are a joke now.

[@tamiz8895]

But can the new tech double as self-defense?

[@roscoejones4515]

Just need to buy led bulbs for them.

[@gringostarr69]

I cant get the end cap out.. Any solutions?

[@ModernDIYProjects]

Try removing the bulb and pour oil or baking soda solution in from that side to loosen it up. If you can get either side open then try to soak the end cap side in a bath or WD-40 for a few days. Allow it to penetrate the threads.

[@Simba-wh4pe]

The front part isn't threaded. There is a circlip that would need to be removed to pull it out from the front.

[@michaelgriffin5279]

Remove. Button cover. There is. A small hole in button, use small flat head. Screwdriver. To. Loosen. Set screw to remove. Front inner. Section.

[@simonsignolet5632]

2mm allen key (aka hex key).

[@magaman3048]

What if you can’t unscrew the cap?

[@ModernDIYProjects]

In that case soak the cap (the tail end of the light) in vinegar. That should hopefully loosen it up.

[@Shoitaan]

What oil? Like vegetable/cooking oil or motor oil?

[@ModernDIYProjects]

YES!

[@MartiBagwell]

I can’t get the bottom off to get to the batteries

[@ModernDIYProjects]

Try soaking it in vinegar or baking soda for a few days. If not try penetrating oil. It's s slow slog to fix these guys. It took me several days maybe a couple of weeks time to accomplish it.

[@ecuarrrrr]

What kind of oil?

[@ModernDIYProjects]

Any oil will do. Cooking oil, Motor Oil, Penetrating Oil, Transmission oil, anything that can act as a lubricant to loosen up the batteries.

[@leedellenbaugh2733]

What about WD40?

[@sd1200hd]

Kool. I’ll let you know how it goes.

[@dakotap3008]

I bought my flashlight online for around $70. The batteries leaked and I tried to get them out. Finally I was successful. However, when I put fresh batteries in, the flashlight didn’t work. So what did I do? I bought another one. After talking to the manufacturer, they said when it’s not in use, to take the batteries out. Who uses their flashlight every day? So there will be times it’s not in use. And I didn’t want to put the batteries in every stinking time I needed to use it. They were probably in the light a month. Wudda ya know, the exact same thing happened. So now I have two problems. In your video you suggested putting oil inside. Would that be plain cooking oil? And, how do you check to see if the batteries will come out, without spilling the oil all over the place. Can the same oil that you put in be re-used or add new oil? Is it a problem if some residual oil remains in the light? You said to pound on the batteries to get them to dislodge. However, the light I have has four AA batteries. Two with the positive up and two are positive down. Is it okay to pound the two batteries that are positive side up? I know, tons of questions, but I really need your advice. Sorry this is so long. I was, obviously, full of questions. Thank you.

[@ModernDIYProjects]

I'll be brief as I can. Any oil will do, cooking, motor, transmission, gear, literally ANY oil will do. Do not reuse the oil since it will have acid in it. Clean oil will neutralize the acid every time you refill it. Drain out as neatly as possible but a mess is likely. Drain oil first before attempting to dislodge. You will know if they get loose or not. Always pound on the batteries with a wooden stick. No chance of arching or electrical discharge. Residual oil is OK since it will prevent then from exploding again in the future. Hope this helps.

[@dakotap3008]

@@ModernDIYProjects It definitely helped. It brought one flashlight back to life. Now I’m working on the other one. Even after soaking it, there’s still some residual acid that I can’t scrape off and, so far, the oil hasn’t helped one stubborn area. But I’ll keep trying. Thanks so much for addressing my lengthy comment.

[@Starcrunch72]

#theDenofTools sent me here

[@ModernDIYProjects]

Excellent, welcome aboard! The Bear is a good friend.

[@leebird4690]

What kind of oil do I use to get the battery out that’s stuck inside my mag light

[@ModernDIYProjects]

I used regular motor oil, but you can use any type of oil you have handy. Cooking oil is fine also. It is just to lubricate and break down the acid.

[@leebird4690]

Ok I did that it’s turning slowly

[@leebird4690]

I’ve poord oil into my mag light and it drips down to were the light goes

[@ModernDIYProjects]

@@leebird4690 You mean it is dripping out the other end? That's fine. Just put a container under it to catch the oil. It means it is separating the batteries from the case. If there was no room in the case the oil would not be able to leak out, so it's working. The oil will not hurt the light bulb at all.

[@leebird4690]

We are trying bleach and it’s working

[@leebird4690]

I put oil down in agian and it slides close to the end of the tube I all I could use is a knife

[@aliciablumenthal8312]

I can’t get the lid off

[@ModernDIYProjects]

Try soaking it in penetrating oil for a few days.

[@zamraqayum]

and this guy didnt relise how the light is put together under the button rubber that pull out is a t6 or t8 bit find the right tool and the button assembly comes out

[@ModernDIYProjects]

Good info, but realize that they are not all assembled the same. Mine for example is over 30 years old, so assembly methods have changed over the years. Mine has a ring around the button that needs to be unscrewed.

[@zamraqayum]

@@ModernDIYProjects yeah I didn't account for that but great video though what dod you think of the LED conversion kits for these lights I've got a 3d maglite and I and I bought a LITT Ultra-Bright 350 Lumen Maglite LED Upgrade Bulb 3-6 Cell C & D Model From amazon cost about £$12-15 Great and cheap upgrade

[@Geoff4822]

These torches are utter rubbish. This is the second time I've had these antics in 3 years. the last time I drilled the b'stads out. This time I am trying your oil idea. I keep the torch handy for emergencies but unless you have 15 emergencies a week you don't think to check the batteries - and then when you have the emergency you are in the dark and unable to put new batteries in. You can get a rechargable and much brighter torch from Toolstation for £13 made by Ring - and I think that's the way to go.

[@ModernDIYProjects]

Well, they were the best back in the day, but today like you said there are many more alternatives.

[@clearingbaffles]

Maybe BUT Aluminum is a very reactive element

[@dodgeramsport01]

Glad you didn't switch to the godawful led's

[@WideCuriosity]

A company should not be proud of a product that has such a basic design flaw that they have failed to correct after all these years. That is not a good reputation.

[@ModernDIYProjects]

Yea, but back in the day they were the best deal in town. Now there are so many better flashlights out there that you are right. They are not the best any more. But for us folks that have one from the old days it's kinda a cool oddity. Kinda like folks that ride Harley's. You know they are not the best or fastest, or most comfortable, but they are still cool. 😆

[@simonsignolet5632]

GaryX - The "design flaw" is with the batteries - which aren't manufactured by Maglite. The rest is physics that Maglite can't do anything about it.

[@simonsignolet5632]

@@ModernDIYProjects I bought my 3D cell Maglite in 1980 and, yes, they were the bees' knees, back then and worth the £25 I paid. My friend has a "better" torch that's smaller and insanely brighter than my 3D was (even with my 20+ year old LED bulb) - but his batteries are non-standard, very expensive and impossible to replace other than by mail order. My Maglites take D cell, AA and AAA batteries - which are available anywhere, conveniently and quickly. I don't need the overkill brightness of his torch so I prefer my 3D and 2AA cell Maglites. When the batteries die, *ANY* of my more modest Maglites are better than his non-functional torch - until he receives his new batteries in the mail. KISS principle. Well maintained, my Maglites should last forever, presuming that when D and AA cell batteries become obsolete adapters for newer batteries types will be made. I grew up watching my father use (what are now) antique tools. Even when better, newer tools were available, he often DIDN'T upgrade - he didn't need to. He had experience, knowledge and skill with his tools, he could repair well virtually ANYTHING - and, on reflection, anyone seeing him use his "old tools" could see that he was a true, skilled, "old school" craftsman. These "old friends" set him apart from the many armed with newer tools who couldn't reach his level of quality. I use various types of torches, including rechargeable work lights. But outdoors in horrendous weather, I can rely my life on my Maglites - even underwater. I grew up with the policy of buying tools for life so many of my most used tools are somewhat "elderly" now. Just proves how reliable they are. One final word on my Maglites: when my hair turned grey, I didn't mind. It shows that I've maturity and experience. I tell people my age (58) without shame or embarrassment - perhaps with a little pride given that I've an equivalent of a PhD in the University of Hard Knocks AND am still going strong. Most of the kit I use in the great outdoors reflects my good choices of DECADES ago - and they're STILL very good choices amongst modern counterparts. I can MORE than keep up with the young armed with the latest "super cool" kit - and know that, in the long run, my choices of kit will endure for longer than many of their choice items of kit. My Maglites are an unintended statement of my ethos. "Old Sweat's Kit".

[@dblankenship6947]

What type of oil?

[@ModernDIYProjects]

Any, doesn't matter. It's just for lubrication.

[@dblankenship6947]

@@ModernDIYProjects thank you so much for your prompt reply. I appreciate that you took the time to make this video.