DIY LED Flashlight: Dimming & Touch Upgrades

Prepare the XML T6 LED and the casing for a compact straight flashlight. In the absence of a readily available dimmable small straight driver, consider crafting a customized driver using components like 7135 and 8022WS. If a professional heat transfer device is not accessible, manually carve a board using a double-sided copper-clad board. Alternatively, affix two 502 boards together. Employ a compass for precision in drawing a circular pattern and a file for shaping.

Given that the 8022 operates on a power-on judgment mode, it is advisable to dismantle an electrolytic capacitor shell to fashion a switch. While this approach may exhibit some instability, it remains a functional option. (Connect OP1 to ground and regulate OP2 for on/off). This setup facilitates seamless transitions between infinite and three-level dimming.

Critical to the process is the connection of the touch switch. Use a bit to drill a hole, ensuring the LED and driver compartment are pre-assembled and tightly secured before drilling into the driver compartment. Fashion a button using resin and insert it into the designated hole.

Shape a circular PCB using a file, ensuring precise sizing. 

Affix the spring PCB securely.

Proceed to solder the circuit.

Prepare for the creation of a switch.

If opting to disassemble a hard drive bearing ball for a ball switch, bear in mind that steel balls may not offer optimal conductivity due to high contact resistance. Alternatively, using solder balls can prove effective.

Connect the switch and touch wires meticulously.

Install the switch securely.

Extend the touch wire appropriately.

Achieve a successful assembly.

The resulting illuminated image is displayed below.

Consider enhancing the tail switch by incorporating an LED light. This addition serves the dual purpose of indicating power status and providing a convenient battery reference.