Originally Posted By: 6pac
I carried 2 of my maglites to a machine shop aroung here to do the very same thing, I even had the caps for both ends. The gentlemen there told me that it would be "real expensive to chase those threads", he acted like he didn't wanna do it. So I left. Was it that hard to do?


There are two ways that I know of to cut the treads. Either by lathe or tap. A tap in that size is very expensive and can probably distort the tube if not done properly. The other way is the way my machinist cut them which was on a manual lathe--there is plenty of labor involved plus machine bit wear and tear. The tube also has to be cut evenly so the cap will seat properly onto the tube when tightened--and the tube end needs to has a slight chamfer to help the o-ring 'get skinny' (without tearing) and seal into the tube.