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.