Summary

18650 to 2 D Cell Adapter

Instructions

This adapter is for 2 D cell flashlights. This adapts a single 18650 battery to replace 2 D cells. Print two of every thing for a 4 cell flashlight.

Extra parts needed:

Instructions for assembly:

Strip back 1/2" of insulation. Push through bottom piece. Then flair out the strands.
Take penny and insert into bottom of the piece. You will need a pair of pliers to seat the penny against the flared out wire. See photo #3.
The top piece is two pieces. Super glue the part without holes onto the second piece. Use a battery to line up the hole for the battery.
Remove battery after glue has activated.
Now slide wire through hole and cut the extra off. Pull wire back out and strip back 1/2" of insulation. Slide wire back through hole in top piece. Cut away any wire strands that prevent wire from laying flat in bottom of the hole. See photo #2.
Now super glue ends of dowels and press into top until they bottom out.
Place several drops of glue on the dowel ends. Then press the bottom piece onto the dowels. Be sure they are flush with the bottom of the bottom piece.
Push the 18650 battery into hole on top firmly setting the battery against the flared out wire.
The overall length from positive to the negative end should be 120mm.
Test for continuity.