I’ve recently installed a Nite Ize Maglite LED Upgrade in my mini-maglite. I’m really happy with the way it has worked. Here is more on how to install a maglite LED upgrade kit and some of the pros and cons of getting one.
Anyone who owns a standard Maglite flashlight knows the durability and dependability of the engineering marvel that swept the nation after
Easy to do, and easy to undo if you change your mind
the first one was introduced in 1979. Every size of flashlight is made with the same quality that the founder, Tony Maglica, put into the very first model. The customer is given a limited lifetime warranty that is honored with few questions if the unit must be replaced because of a defect or damage during use. People in every industry use Maglites in professional and personal settings for safety in the most strenuous weather conditions. Because of their quality, a Maglite is never thrown away, so when LED technology came along most owners of these flashlights stayed with the standard reliable product. The market waited for the company to produce Maglite LED upgrade kits and eventually some conversion kits were produced in response to the third party companies who attempted to meet the demand.
Advantages of a maglite led kit
Third party Maglite upgrade kits will most likely void the lifetime warranty of the Maglite, so using a kit that will not do so is imperative. An LED module and a replacement tail cap switch are included since the combination must be used to produce the DC current required by the LED. When replacing these two parts, special care must be used to replace all of the other existing parts in the reassembly process. A brighter light beam will be noticed as soon as the switch is turned on. The same beam-focusing characteristic is retained after the conversion so the beam can be made broader or slimmer for the perfect view. Over time, the user will notice an extended battery life even when the unit is used more often. Purchasing a Maglite LED conversion kit is relatively simple because each one is based on the number and size of the battery cells in the existing unit.
Disadvantages
Cost is the immediate disadvantage to upgrading a Maglite, but the longevity of the product will offset the price of the kit as long as the warranty has not been voided by using a third-party upgrade. After the unit is reassembled, the light will not always illuminate. If this happens, the LED module must be removed then rotated 180 degrees to flip the pin positions. Even though the LED is much brighter, most users notice that the reflector is not optimized for use with an LED like it is with the standard light bulb. Since a voltage regulator is not included with the upgrade, rechargeable batteries will not operate a Maglite that has been converted to LED. Market demand may require the production of an upgrade kit that can run on rechargeable batteries. You may also want to consider whether you need a dedicated headlamp, in which you could consider something like a Petzl Tikka or similar headlamp rather than investing in upgrading your Maglight.
Conclusion
Even though some limitations are noticed after the conversion to LED, the Maglite is still the most loved flashlight on the market today. Brand name upgrade kits were introduced slowly in hopes that most customers would simply replace their beloved flashlights with the newest model directly from the company. As usual, the market preavailed, and the company had to respond to the lifelong customers who would not give up their cherished flashlights. Even the most weathered and abused unit can be upgraded to lengthen its useful life while producing a brighter beam and using less battery energy.
Do it Yourself
If you are a little bit handy and know your way around electronics and resistors you can make a DIY maglite upgrade kit on your own. It need not cost much. There is a great site here with some pictures on how to do it here. In short, it essentially entails getting a single super-bright LED, switching out the existing batteries for 3 N sized batteries (instead of your existing 2 AA) to bump up the voltage. You then need to drop it back down again a bit using a resistor, and you simply trim and push the white LED into the top of the torch.
Okay, it is a bit more complex than that, but not by much.
If it is still a bit too complex, you could get a simple kit. They are on sale from Amazon.com and are made by TerraLux. They are really simple, drop right in and cost about $15.
It is really simple to use and gets great reviews. I haven’t tried this specific one yet, but people say that it gives a really bright light and is much brighter than the competing one made by Nite Ize. I can’t comment on this. Some users have also complained about its reliability saying it stops working or breaks after a while. Again, I can’t speak from personal knowledge on this.
Installing the Nite Ize Mini-Maglite Upgrade Kit
I found the nite ize led upgrade was really easy to install. Here are a few photos explaining the full process. Rest assured, it is easily done and takes just a few minutes. The instructions that come with it are about half-way clear so the photos should help.
The kit is pretty clear and easy to understand
The kit is reasonably nicely packaged and is pretty self-explanatory in terms of which size you are getting (ie AA for a mini-maglite, C or D for the bigger versions).
What when you open the package that you don’t rip or cut the instructions as they are printed on the inside, so open by cutting along the bottom edge.
Remove the top of the mini maglite, including the reflector and existing light bulb.
You then replace the reflector with the one in the kit and insert the Led module into the top. The two connectors fit exactly into the slots provided for the normal bulb. If the LEDs fail to light up, remove the module and turn it 180 degrees (so that the opposite little leg, or connector, goes into each hole).
Then replace the top and the lens and you are done.
TerraLUX TLE-5EX MiniStar2 Extreme LED Upgrade for Mini Maglite 2AA Flashlight
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 List Price: $23.96 Sale Price: Too low to display Availability: Usually ships in 24 hours Eligible For Free Shipping 
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Product Description
TerraLUX MiniStar2 Extreme LED Upgrade for Mini Maglite 2AA Flashlight has a white LED light that never burns out. It has extended battery life that lasts 3 times longer than incandescent bulbs and maintains focus of MinMag flashlights.
Details
- Bright white LED light
- LED never burns out
- Extends battery life to 3 times longer than incandescent
- Save money on replacement bulbs and batteries which pays for itself
- Maintains focus of MinMag flashlights
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