6 AA cell battery holder conversion instructions

Use 6 AA cells in place of 2 D cells for six cell voltage in a 2D cell flashlight.
The 6AA battery holder comes set up with the cells
wired in series for 9V operation. To make it useful to
get six cell (9V) voltage in a 2D cell flashlight, front
and rear contacts need to be added.

  • This modification allows use of 6 cell incandescent
    bulbs in a 2D cell flashlight for increased brightness

  • This modification allows use of 6 AA NiMh cells (7.2V)
    to direct drive Luxeon V LEDs is 2D cell flashlights
The front end of the battery holder has a lip and two rivets
showing. As shown, the left rivet is the + positive contact.

Solder a one inch wire from the + rivet to a positive contact
board.
Solder an insulated wire to the - negative rivet and rout the wire
as shown the length of the battery holder.
Solder the end of the wire to a brass washer and glue in place
centered on the back end of the battery holder.

Allow the epoxy to harden before continuing.
Epoxy the contact board in the center of the holder end. Allow the
epoxy to set up before proceeding.  

Verify proper operation of the completed battery cartridge. .

That's it, the holder is now ready for use...