Bosch 12V flashlight with adjustable head

This is a remix of my Milwaukee M12 system flashlight adjusted to Bosch 12V system battery. It has a head with an adjustable angle, made from MR16 led bulb.

BOM

To assembly it, you will need:

• 3d printed lamp head.
• 3d printed upper piece of the body.
• 3d printed lower piece of the body.
• 3-5W MR16 led bulb with a radiator with M28x1 thread (see photos)
• 2x 8mm length M3 screw
• 3x 16mm length M3 screw
• 2 pieces of 6.3mm spade male connectors
• 1 piece of 21x15mm rocker on/off switch
• 10cm of 2-wire cable

soldering iron Notes

Assembly process is very similar to Milwakuee version so check it to see all assembly steps. I had to bend rocker switch connectors as the switch cavity is a few millimeters shorter than in Milwaukee version.

Please note, that the battery direction is opposite to the one used in other Bosch tools. I did it that way so the switch can be placed closer to the battery and the whole flashlight is shorter. It shouldn't matter in practice.

My led bulb uses almost 5 Watts and gets really hot (over 60°C) so printing lamp head with plain PLA may be not enough. I used PETG and it is holding ok. PLA could be probably used after "baking".

There seems to be a lot of MR16 led bulbs with M28x1 thread on aliexpress. I checked MR16 bulb from this page and it fits the thread perfectly. Bear in mind that power of those bulb is greatly exaggerated, 9W bulb in reality draws around 3W.

Print Settings

Rafts: 

Doesn't Matter

Supports:

Yes

Resolution: 

0.2mm

Infill:

25%

Notes: 

Support is needed but it is very easy to remove it with long pliers, and almost all surfaces touching support are invisible after the assembly.

I used X-Acto knife to fix cuts around four locking pins in the lamp head part to ensure that all four locking pins are working as springs.