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Maglite mod circa 2004

mudbone

mudbone

SM 2004
Full Member
Joined
Oct 20, 2003
Messages
175
Location
Rixeyville, VA
After reading thru the various mods described on the board, I snagged a Maglite 3-D-Cell model a Wal-Mart. I looked all over Fredericksburg, Culpeper and Warrenton, VA and couldn't locate a mounting kit anywhere. I finally found one online at Cases4Less.com. Once the brackets came, I noticed that my 2004 Z71 doesn't have the screws already installed on the top of the access door. The area is smooth as my two-year-old's behind. I was concerned about trying to secure the brackets with simply drilling and screwing in self-tapping fasteners into the thin plastic door.

I mulled this over for a few days and now have come up with what I think is a unique and effective solution to the problem. While at Lowe's picking up some "honey-do" items for the long weekend, I scoured the hardware section and found four plastic inserts similar to those used to secure license plates to automotive bumpers. These are smaller though, sized to accept a #8 sheet metal screw. I carefully drilled 4 - 5/16" holes in the underside of the door -- taking care not to drill all the way through to the outside!! I popped the inserts in and screwed 4 - #8 x 1/2" screws into the brackets and snapped the Maglite into position. It fits snug as a bug, and should not strip out even after years of use.

I left the camera at work, so I'll post some photos next week. Sorry :cautious:

My only beef -- while searching for the brackets -- and after getting a black Maglite at Wally-world -- I found a green Maglite at Target. That would have looked extra-cool with my DGM Z71. Oh well, maybe I can talk someone into buying a green one for trade ;)
 
Good solution and hopefully will help other 2004 owners wanting this mod.....

I still keep mine inside under rea seat so I can get to it easier...
 
The 2004 Avy has the same smooth saddlebag interior lids with no screws as the 2003. Here's what I did on my 03' (And yes, I have a dark green metallic mag-lite that matches my dark green metallic Avy.

Just completed my Mag-Lite Mod on the passenger side compartment/locker.

Word of caution - I placed my first bracket near the front of the compartment/towards front of truck, when I drilled it only went in about a 3/8 of an inch, or less; there was a metal plate right below the plastic. Was no problem as I made the screw just long enough to go through mag-lite bracket and the plastic of the locker door. But you may want to consider moving the bracket towards back to avoid bracket. The metal was encountered approx 1 and 1/2 inches from the front inside edge lid gasket. If you move the bracket be sure to consider the jack handle location as a potential obstacle.

Also, I used medium thread screws, colored black, and I used a clear two-part plastic epoxy as additional hold as I don't trust just the screws. Appears to have worked out well. Very strong. I cannot pull off bracket without ripping lid. I sanded both the area of the lid and the brackets, then cleaned both with alcohol prior to glueing the brackets to the lid. However, using epoxy means this is a permanent mod, and if a clip breaks I'm scr*wed!

I used a 3-cell mag-lite as I have read some members mag-lites were falling from the clips. I am hoping as a 3-cell is lighter than the four cells that this wont happen? I also choose 3-cell as the 3-cell comes in dark metallic green (same color as truck - COOL).

Good luck to future modders, was an easy mod. Just drill the lid slowly then check your depth with a nail or something to determine how long of a screw you can use. The depth will vary by bracket location. You don't want the screws to dimple the locker lids on the outside over time. I custom cut my screws to length using wire cutting pliers and a lot of squeezing!
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Sorry I don't have a digital camera, so no photos. It has been 4 months since I did this mod and the clips have held very well. There are many posts in the mag-lite mod thread that discuss the smooth with no screw lid mounting options.

Regards,

SpottyJ
;D
 
SpottyJ said:
The 2004 Avy has the same smooth saddlebag interior lids with no screws as the 2003. Here's what I did on my 03' (And yes, I have a dark green metallic mag-lite that matches my dark green metallic Avy.
Click to expand...

Well not all '03s have the smooth lids, I have an '03 and it had the screws where I could easily add the mag light clips were in place and easy to use. Guess mine was one of the very early ones though.

garage_mod-664-1068595974.jpg
 
As promised, here are some photos of my Maglite mod -- finally:)

 

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Here's another one. The first one and this one show the plastic inserts on one side and the mount on the other.
 

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Mudbone,
I looked everywhere for the hole clips that you used and could not find them. I went with teksavy's mounting instructions on the Mag-Lite Mount For Side Compartment thread on my 04 and so far so good. If they pull out I guess I will continue looking for the one's you used.
Thanks for the post on the 04's, it did get me looking in the right direction.

Bass Fisherman
 
good job on mounting the MagLite. i too had this on my '02. when i got the '04 and saw no mounting screws i was disappointed. i just stuck the light in a bag i carry some other stuff in.
 
im a little bit confused about the small plastic fasteners

how do they attach to the plastic of the lid, and what advantage does this have over just screwing into the lid?

thx
 
The fasteners have about 3/8" depth (or more - it's off the top of my head) of thread area to grip the screws. These things look like smaller version of the plastic inserts used on bumpers to attach license plate screws. I drilled a fairly large hole and popped the inserts into those holes. That gave me a lot of thread area to support the mounting screws. My concern (and reason for using these) was that I felt that constant tugging on the mounts (to pull the flashlight off for use) would cause the self-tapping screws to pull out of the thin plastic shell of the cubby door.
 
mudbone said:
The fasteners have about 3/8" depth (or more - it's off the top of my head) of thread area to grip the screws. These things look like smaller version of the plastic inserts used on bumpers to attach license plate screws. I drilled a fairly large hole and popped the inserts into those holes. That gave me a lot of thread area to support the mounting screws. My concern (and reason for using these) was that I felt that constant tugging on the mounts (to pull the flashlight off for use) would cause the self-tapping screws to pull out of the thin plastic shell of the cubby door.
Click to expand...

ok im stupid i guess i still dont get it (sorry). im just missing something here.

do the inserts screw into the holes? do they just stick in there? what keeps the whole thing (insert, bracket, and flashlight) from falling out?

thx for following up.
 
I only bought four of the inserts, and I'm afraid to pop one our for a photo. I'll try to describe them better.

Each instert has a plug on the back side (away from the threads) that has two crossed splits. The slpits allow for some compression as you would push into the drilled hole. There is a shoulder on the outmost end of the plug that once it pops into the hole, it cannot come out easily. It took a fair amount of thumb pressure to get them in the holes I drilled. The inserts are white nylon plastic.

As I said above, I got them in the hardware section of Lowe's out of one of those "miscellaneous fastener" drawers. There was a whole ailse of this stuff.

As an aside, I recommend spending a half-hour looking at all the different types of things in this area of Lowe's (or other similar store). There are thousands of cool little parts that you might remember one day when you have a problem to solve ;)
 
i think maybe i understand. ( finally =] )
the insert is hard to push in there, and whenyou put the sheet metal screw into it it expands a little and makes an even better connection/seal? correct me if im wrong here.

thanks for the extra info. i couldnt understand what kept the insert in the hole. i was thinking for whatever reason that if it was just pushed into a hole that the insert would actually be more likely to just fall out that if you screwed directly into the plastic. but from what you are saying now it seems like it makes a really tight connection when you cram it up in there and the put the screw in.

again thanks for the extra info. ive got my brackets ordered finally (been meaning to for a month) and ive been pondering how im gonna do it on my 'presently-lid-screwless 04'
 
avatar said:
...but from what you are saying now it seems like it makes a really tight connection when you cram it up in there and the put the screw in.
Click to expand...

You got it, Avatar! And yes, the screws do expand the plug for a tighter fit. I forgot that aspect in my description;) I've been *using* my MagLite alot lately and the mounting is just as secure as the day I installed it. This mod is so functional. I've had flashlights for years, but never seemed to be able to lay hands on one when I need it! Now I always have one where I can find it.
 
Here's a question as far as MagLite mounting... has anyone tried using anything like Gorilla Glue or something of the sort as opposed to drilling the plastic lid? I was just curious if anyone has had success going that route? I don't know how sensitive the plastic is and if a superglue type product would essentially eat through it or not. Just a thought on a different way to try to mount the brackets on a smooth 03 lid. Thoughts?
 
my clips came in today and i gotta admit im a little bit surprised at how tightly they grip the light.

i can see the concern about small screws now. i wouldnt be concerned about the light falling out when im driving around.... id be more concerned about pulling the whole thing out just trying to get the light out of the brackets...
 
hey mudbone i looked around town and its funny because no other hardware stores would even acknowledge that these things exist.

finally i went to lowes and sure enough they had some like you said.

does this look like the same size you had? you drilled 5/16 and it looks to me like a 5/16 hole would do the trick with these.

 

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avatar said:
...does this look like the same size you had? you drilled 5/16 and it looks to me like a 5/16 hole would do the trick with these.
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That is absolutely exactly what I used. Same package even :)
 
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