HFT Luminar Outdoor Popup Lantern 18650 battery & charger modification

One 3D print, a few parts and no more buying AA batteries. Rechargeable with micro USB
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updated November 22, 2023

Description

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This requires no modification to the lantern itself other than two solder connections. I know of two different types of these lanterns. Type 1, as I call it, is the older version that I have had for the last year or two. Take off the bottom cap and look at the threads. You will see four sections of threads.

After making my first adapter, I bought two more lanterns from Harbor Freight. To my surprise my adapter would not fit. The threads had changed. They are a little finer pitch thread. Look in the bottom cap and you will see two long sections of threads. This is what I call Type 2.

Printing Specifications: Even thou there are threads jutting out I was still able to print with no supports. I used no brim, must have good adhesion on base to prevent distortion of threads. I used generic PLA with 30% infill, starting the first several layers slowly, about 50% on Ender 3 with layer height of 0.15. made periodic boost in speed up to 90%. Top and bottom two or three layers, sides three layers. I ran temp at 203C for better layer adhesion. I used TinkerCad for the design. It has limitations of number of facets in circles which shows up more with large diameters but still looks pretty clean when assembled.

Post Printing: After printing, test thread fit. Be careful the threads can be easily cross threaded. Cap will start loosely, only catches last few threads. Adapter to base is a pretty snug fit. Once thread on, work it back and forth several times to wear threads to a good fit. I used a little lithium grease, that makes it turn smoothly.

Electrical Wiring: Do this outside the adapter. Use dissimilar wires for positive and negative connections. Low current use, 20-to-24-gauge wire is fine. Solder wire from positive pole on 18650 battery to B+ on board, negative pole on 18650 battery to B- on board, around 2 1/2 to 3". Wires from board to lantern base around 6". Solder appropriate wires to Out+ and Out-. Snap battery into holder, as in picture, slide board into adapter holder and press down into frame. Hot glue board into place to prevent coming loose. Solder positive wire on to positive single pad in base and negative wire on to single negative pad with spring, as pictured.

Assembly: Pull up lantern top to make sure it works. Turn off and plug in micro-USB into charging port. Red LED on board will light. Nothing getting hot, no smoke, great. Unplug charger and get ready to screw adapter to base. Turn backwards or counterclockwise several turns to twist wires. Align and screw adapter to base until fully seated. By doing it this way the wires will unwind some and makes sure the wires will not be drawn up to tight and pull the board up from being glued. When charging a red glow can be seen inside charging port, it will be blue when charged.

Parts needed:
18650 lithium battery - got mine from an old defective battery pack that had some good cells working.
About 18" wire, 2 colors
Solder & soldering iron
Hot glue or some type of adhesive. 
Charging board - bought from Amazon 10 pack (about a dollar a piece) https://www.amazon.com/gp/product/B00LTQU2RK/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1

A PDF file of these instructions have been added to print.

5/2/2023:  I added another model for the lantern to be hung by a hook. Harbor Freight Luminar Lantern Hanging Hook by JEO | Download free STL model | Printables.com

11/21/2023: I received a comment today about USB cord storage. It would be good to have that capability. After exploring that possibility, I noticed it has one built in by the top cover. The last picture shows a 1-meter cord coiled in the top cover. Thanks to Steve Stevens@SteveStevens_1385497 for that suggestion.

 

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