Fabrication of
Flashlight Holders

 

I have often times had to dig through drawers, tool boxes etc. in order to find a flashlight. Many times I found that flashlights on board are merely tubular devices in which to store dead batteries. I often thought that if they were stored where they were handy I might check the batteries more often. Flashlights should be like anything else on a boat and have their own proper stowage location.

I decided to fabricate two different sizes of holders since I already had four identical penlights that used two AA batteries and one that used three AA batteries. The smaller four are to be placed at the head of each settee berth, at the head of the V-berth and one in the head. A larger version was also fabricated to be placed near the companionway and engine compartment to hold the larger LED Mini Mag Light.

The three piece holders were designed to fit my specific penlights and fabricated from scraps of teak and satinwood that I had left over from other boat projects. The dimensions could obviously be changed to suit any style flashlight. I started by cutting the upper blocks from some scrap 3/8 in. teak. These were cut to 1 5/8 in. x 1 5/8 in. Using a hole saw slightly larger than the diameter of the penlight I cut a hole all the way through in the center of these blocks. The lower blocks were cut from some 3/4 in. teak stock to 1 5/8 in. x 1 5/8 in. With a hole saw of the proper diameter I drilled to a depth of only 3/8 in. Then using a small chisel and my Dremel tool I cleaned out the hole so that it was now 3/8 in. deep with a flat bottom.

Next I fabricated the back plates from 1/4 in. satinwood. The back plates for the four smaller holders were cut to 1 5/8 in. x 5 in. and the back plate for the larger holder was cut to 1 5/8 in. x 7 in. The top corners of all the back plates were rounded to a radius of approx 1/2 in. I drilled and countersunk four holes from the back side using a combination drill/countersink bit for #4 flathead screws. Four #4 x 5/8 in. stainless wood screws would be used to attach the upper and lower teak blocks. The back plates were then flipped over and two holes were drilled and countersunk from the front side using a combination drill/countersink bit for #6 flathead screws. These will be used to mount the holder to the boat using #6 x 3/4 in. oval phillips head stainless wood screws.

The below sketch (not to scale) shows the three pieces required to fabricate the holder.



All three pieces of each holder were given five coats of Captain's Varnish prior to assembly. I also lined the holes with red adhesive backed felt to eliminate the possibility of rattles when motoring.

The last step in the fabrication process was to clamp the teak blocks to the back plate and match drill the pilot holes for the #4 wood screws that would be used to assemble the holders. With this done, they were assembled using West System epoxy and the stainless # 4 screws.




Shown below is a photo of one of the holders mounted over the starboard settee berth.

Material Required:

4 pc Satinwood 1/4 in. x 1 5/8 in. x 5 in. (on hand) $0.00

1 pc Satinwood 1/4 in. x 1 5/8 in. x 7 in. (on hand) $0.00

5 pc Teak 3/8 in. x 1 5/8 in. x 1 5/8 in. (on hand) $0.00

5 pc Teak 3/4 in. x 1 5/8 in. x 1 5/8 in. (on hand) $0.00

20 ea #4 x 5/8 in. flat head stainless steel wood screws (Ace Hardware) $1.40

10 ea #6 x 3/4 in. oval phillips head stainless steel wood screws (Ace Hardware) $1.20

1 pc Red felt (adhesive backed) 12 in. x 12 in. (Michael's Craft Store) $1.00

Captain's Varnish (on hand) $0.00

West System epoxy (on hand) $0.00

Total cost: $3.60


Tools required:

Miter box and back saw

Jig saw

3/8 in. Electric drill and assorted drill bits

7/8 in. hole saw

Combination drill bit/countersink for #4 flat head screw

Combination drill bit/countersink for #6 flat head screw

Finishing sander

Phillips screwdriver


This project took approximately 2 hours to complete (not including varnishing time)

 


Copyright 2008-2015 No duplication of any portion of this website without express permission.
Permission may be obtained by e-mailing the webmaster at
earlylight160@yahoo.com.