How to upgrade cheap flashlight

This is part 1 on this project, I was a bit disapointed of this flashlight, because it was advertised as having the cree XM-L2 led, but in reality it had the older XM-L led, there is not much difference between them, but around week ago, about 2y of daily use, the led died on me. So this is perfect time to upgrade the old led with much more powerfull XHP 70 led. I hope that this series will inspirate you to try something like this yourself. I will make design for PCB that can be ordered trough manuefacturers.
This video covers the basic testing for the driver.

[@mrdhaliwal8228]

Could we please ask the driver type? Sadly I didn’t get more than 2.5amps on the AliExpress driver which claims 5amps

[@torontovoice1]

Hello my friend. So I changed the bulb as you described. I did not put on the plastic part like you because it did not fit. After one minute, the bulb burned out. Not sure why? Your must have been the same
Any idea of what I do if the cree bulb is bigger than the previous one? Do I need to make a plastic part to isolate the electrical current so that it does not short? Anyway, it was fun changing it, top bad it does not work. I have another build a bit smaller xhp70 6 v . The flashlight is identical to the one in your video. Thanks. Any suggestions ?

[@4sIElectronics]

I'm not exactly sure if you are talking about the 3D-printed part that keeps the led with its heatsink star centered or the small reflector. I also had some trouble getting the reflector back on, which was mainly due to the solder joints rising too high. Which kind of driver do you have on your flashlight? Because the original (atleast mine) does not step up the voltage, so it doesn't even light up with it. Also, how is the led mounted on your flashlight? (the bottom of the star heatsink should be electronically isolated) with this kind of power, the cooling becomes a big problem, and that is pretty much the only problem with my flashlight. The highest power can be used pretty much only if the surrounding air temperature is below -5 deg C... I thought that I lost all the footage making the heatsink, but I managed to recover some of the pictures. Here is a folder where you can find some pictures of the heatsink mega.nz/folder/fs93XDjB#fP3gwI955aXRITtRxp-vCQ

[@torontovoice1]

@@4sIElectronics wow thank you so much. I was not expecting such a detailed and comprehensive answer. I'll send this info to the chief engineer karma and see if we could get this fixed. Thank you again, I really appreciate your response.

[@nejdet5155]

Thanks for your project, can I already make xml T6 flashlight p70 or p90? With just one solder! There is a 20cm flashlight!

[@ryukimura7302]

I wish you could upgrade your audio better