A couple of weeks ago, Target recalled LED flashlight gift sets due to fire and burn hazards. BJ’s Wholesale Club is now doing the same with LED flashlight sets sold at their stores from July 2011 through December 2011.

BJs is recalling about 41,000 “Safe to Go” LED flashlight family packs. The flashlights can heat up, smoke or melt when turned on, thus posing fire and burn hazards. There were 2 reports of incidents, with one consumer suffering a minor hand injury.

If you purchased or received one of these sets, dispose of the batteries and then return the flashlights to the store for a full refund. The retail price was about $15.

More Info via CPSC

Craftsman has announced new pliers and cutters that will feature built-in LED lights. The sealed and waterproof LED modules are built into the pliers’ pivot hubs and direct a precise (i.e. narrow) beam of light towards whatever you’re working on.

The LEDs are powered by 3x 392 watch batteries and are user-replaceable, with an auto on-off circuit helping to extend battery life.

There will be 3 styles available – needle nose pliers, diagonal cutters and linemans pliers. The tools will be available separately at $20 each, and the needle nose and diagonal cutter combo pack will be $30. ETA is June 2012.

Do you guys think that these new pliers and cutters are neat and potentially convenient, or would you rather use a headlamp or other separate light source to illuminate your work?

Target has voluntarily recalled 55,000 6-piece LED flashlight sets due to a fire and burn hazard. It has been reported that, when turned on, these flashlights can heat up to the point of smoking or melting. Thus far there have been four incidents, including two minor burn hand injuries.

These sets were priced at $10 and were sold from Oct 2010 through Dec 2011. The remedy is to return the flashlight sets to any Target store for a full refund.

Sounds to me like a major design flaw where flashlight bodies and LED modules were slapped together without regard to proper heatsink design. This is why everyone should be cautious of all those “special buys” that pop up during the winter holiday shopping season.

More Info via CPSC

Mini Maglite Pro

The mini Maglite Pro is based off of the same 2xAA design that has been around for over 25 years. It features a new latest generation LED module, traditional twisty head switch, and what sounds like new power regulation. As with other mini Maglites, the optics allow for spot to flood beam focusing.

Maglite has not yet released final specs, but says that early tests indicate a 200+ lumen output and 2.5 hour battery life.

200+ lumen in a mini Maglite? I’m not going to say “it’s about time!,” but I’ve been wondering when Maglite would join the lumen race. Not that homeowners and casual flashlight users need 200+ lumens, but Maglite must be have been losing considerable market share to cheap high-power models such as the Nebo Redline, which is currently $22 on Amazon.

Mini Maglite Pro Plus

As the name suggests, the mini Maglite Pro+ offers a few extras not found in the basic Pro model. First, there’s a new electronics package to help maintain the dazzling brightness high output setting. Second, there’s the addition of a low output/maximum runtime setting.

Early tests show a high output of over 210 lumens, and more than 10 hours of runtime on the low power setting. Maglite says that a unique switching system lets users toggle between high and low output modes.

The one thing we don’t like about the current mini Maglites is the multi-mode electronic switch, which toggles between 100% power, 25% power, blink and SOS modes, which aren’t really needed in a basic flashlight. The new two output mode is a welcome simplicity.

Comparison

A mini Maglite we picked up during the holiday season has two brightness settings as well – 77 lumens on high and 25% at low, which is probably around 20 lumens. Runtime is 10 hrs 45 mins on high, and 31 hrs 30 mins on low.

Based on  these specs, we surmise that the Pro+ low output setting may be in the neighborhood of 60-75 lumens in order to achieve a 10-hour runtime. It’s good to see Maglite catch up to competitors, but we hope they try to be cautious about playing the lumen race game.

Pricing and availability information is not yet available.

Mini Maglites via Amazon
Pro and Pro Plus Info via Maglite

Over at Amazon, the Gorillatorch is currently on sale for $20, which is $10 (33%) lower than its regular price. We bought one of these when they first came out, and use it regularly. The best features are its adjustable brightness, long runtime, magnetic feet, and of course its flexible legs.

Buy Now(via Amazon)

The Gorillatorch is available with gray, yellow, blue, or orange accents. Some of Joby’s other upgraded Gorillatorch models also look to be on sale for the holidays:

• Gorillatorch Flare - brighter, water resistant, and an added red LED mode (preview)
• Gorillatorch SwitchBack - very bight and better suited as a lantern
• Gorillatorch Blade - premium model with rechargeable battery and removable flashlight. Unfortunately this one’s not on sale at the moment.

When working on a project, in addition to the right tools, you need good lighting. Sometimes room lighting is not enough and a little extra brightness can make your work go quicker, easier, and more safely. These days, LEDs are are a great way to go, and hands-free products have obvious benefits. Which do you prefer to use more, headlamps or cordless work lights?

The main benefit of a headlamp is that the beam moves with you and can be perfectly aligned with your vision. A major downside is that headlamps are limited in how large and heavy they can be.

Cordless, or even corded work lights, can be a lot larger and brighter. Many offer multiple support and positioning options, but must still be carefully aimed at the work area. Depending on the surroundings, this can sometimes be tricky.

My preference? I tend to use work lights for larger projects, but whip out a headlamp for quicker projects or tasks. Overall, I use headlamps far more, with my current favorite being the Petzl Pixa 1.

Petzl Headlamps (I’ve got 3 of these and love ‘em!)
Dewalt 12V Max LED Worklight (My favorite work light, but it’s sold without a battery. It’s one incentive to buy into the Dewalt 12V Max lineup. Second-favorite is a Craftsman 12V fluorescent model.)

Stanley’s 95-112 tripod LED Flashlight is currently on sale at Amazon for just $7.97! That’s more than 50%-off its regular price of ~$18.

We bought two of these a while back, but didn’t think too much of them until our power went out the first time. Since then we’ve deployed them countless times. The LEDs emit a uniform white beam, and battery life is phenomenal.

At just $8 we’ll probably pick up a few extra and for family members!

Buy Now(via Amazon)

Update: We have just learned that Amazon is also offering a $5 off $25 coupon that works on these flashlights. Stanley $5 off $25 promo details!

If you’re just looking for 1 or 2, and don’t have Amazon Prime membership, Lowe’s has these on sale and eligible for in-store pickup through 11/28. Thanks for the reminder, Colin!

Over at Amazon, this Stanley rechargeable LED flashlight is on sale for half-off! For a limited time (or as supplies last), $20 gets you a 5-Watt LED spotlight with rechargeable battery. It charges in less than 2 hours, and outputs an impressive 192 lumens for up to 10 hours!

Buy Now

Reviews on this unit are excellent. Rechargeable NiMH battery, 5W CREE emitter, ~10hrs of runtime. What’s not to like?!

Update: BF prices have already went into effect. If you order online right now, you also get free shipping to your home, no minimum order!

We already mentioned the Maglite 2D LED flashlight deal in our Lowes Black Friday post. However, we have received news that Lowes will also be discounting Maglite’s 2AA mini-Maglite LED flashlights as well.

Maglite 2D LED Flashlight via Lowes ($14.97)
Maglite 2AA LED Flashlight via Lowes ($10.97)
Maglite 3D LED Flashlight via Lowes ($14.97)

Also available in gray: 2D, 2AA, 3D.

Hurry before supplies run out! The 2D is normally priced at $25 via Amazon, and the 2AA is $18 via Amazon.

In recent years, these have always been quick to sell-out online and in-store. Why? Because they’re great flashlights, and these are killer prices. We usually help this along by buying 2-4 to give away as gifts, and we hope to do the same this year. (Correction: 2-4 was an underestimation as we ended up ordering 5!)

Needless to say, we very highly recommend these flashlights! Also worth mentioning is that flashlights are made in the USA!

Pricing is valid through 11/28.

Over at Amazon, this 10-pack of Cyalume SnapLight glow sticks is on sale for about $10, eligible for free Prime or Super Saver Shipping. Quality 6-inch glow sticks are usually priced at $2-3 each in stores, so 10 for $10 is a pretty good bargain.

There’s a chance that if you order them today with one-day shipping, they will arrive tomorrow, just in time for Halloween! Even if not, glow sticks are handy to keep around for emergencies when flashlights might not be available.

These green glow sticks are waterproof (obviously) and provide up to 12 hours of illumination, The “industrial grade” glow sticks are individually wrapped and have a 5-year shelf life. Hook and gate tops are handy for hanging the glow sticks with cord or wire.

Purchase via Amazon
Additional Cyalume glow stick colors (and also high-illumination military grade ChemLights) are available for a little extra, but these green ones seem to offer the lowest price and longest illumination.

These glow sticks are non-toxic, but try to refrain from putting them in your mouth.

Once these flashlights hit the retail market, we’ll take a closer more detailed look to see if anything has changed from the pre-production models we previewed. If nothing changes, the 2XAA model will probably make it onto our list of the 5 Best LED Flashlights under $20, which we’ll probably have to rename.

A friend recently asked me if I could help him fix his cheap flashlight. He doesn’t remember how much it originally cost, but thinks he bought it for a dollar or two a couple of months ago.

The flashlight only works intermittently, with a higher chance of success when it is jarred or violently shaken. To me it sounds like the problem is with the switch or battery contacts, but perhaps there is a short or broken lead in or near the LED.

Here is my recommendation about how to fix a cheap flashlight… discard it and purchase another one, preferably a better one from a brand that stands behind its products.

My first thought is usually to recommend one of the 5 best LED flashlights under $20 that we discussed a week ago, but a 2AA or 3AA mini-Maglite would also be an excellent choice. Actually, a mini-Maglite would probably be the best recommendation since they’re solid performers and most homeowners and less sophisticated flashlight users are more likely to recognize the brand or styling.

For those that insist on lower priced flashlights, there are many inexpensive LED flashlights over at Amazon, and similar models pop up by the pallet-full at home improvement stores around Thanksgiving and Christmas.

To troubleshoot and fix a cheap flashlight often takes more time, effort and materials than it’s worth. Plus, when these cheap lights stop working properly, the defect is usually irreparable. I’m not one to recommend throw-away products, and often try to steer friends and family away from these cheaper lights.

Maglite 2AA LED Flashlight - this isn’t on our “best LED” roundup, but it is still a superb and highly recommended flashlight. Prices range from $20-$25, but they do drop below $15 every now and then, especially around major gift-giving holidays.

To sum it up, how do you fix a cheap LED flashlight? You don’t, you ditch it and upgrade to a non-disposable model.

With an 800-lumen maximum output mode, the Fenix TK41 isn’t an LED flashlight, it’s a light canon. Wow, just wow. The TK41 has 4-output levels – 10-lumen low-light, 108-lumen mid, 335-lumen high, and 800-lumen turbo modes.

Eight AA batteries power up the TK41, with battery life being about 240 hrs at low, 27 hrs at mid, 7 hrs 15mins at high, and 2hrs 10 mins at turbo output modes. A strobe mode operates at turbo brightness, and an SOS mode at mid-brightness.

Fenix sealed the TK41, making it waterproof to IPX-8 standards. An aircraft-grade aluminum body finished with type III hard-anodized finish means that the TK41 can handle quite a bit of abuse and should be durable enough for even the most demanding applications.

The TK41 is built around a Cree XM-L LED module, and is operated via a dual switch that offers separate on/off and output selection controls. Its dimensions are 1.55 inch diameter, 2.5-inch bezel diameter and 8.4 inch length.

Check price or purchase via Amazon

The TK41 is currently priced at about $130.

Pelican 1910 LED Flashlight

The 1910 is powered by a single AAA battery, and weighs a tiny 1.4 ounces. Its LED outputs a bright-for-its-size (in our opinion at least) 39 lumens and runtime is about an hour. The 1910 also features a Type II anodized aluminum body with non-slip matte finish. The tail cap has a momentary and clicky on/off function.

Check price or purchase via Amazon
More info via Pelican

Pelican 1920 LED Flashlight

The 1920 shares many of the same features as the 1910, but is instead powered by 2XAAA batteries. Output is 67 lumens, and runtime is about 3 hours.

Check price or purchase via Amazon
More info via Pelican

Both flashlights look to be discrete and compact enough for every-day needs, and should be bright enough for even the more demanding users. Street pricing for both models is about $25-30.

We have been reviewing an Elzetta ZFL-M60 LED flashlight, and while our toughness tests are still underway, we thought to do a quick review about what we have seen so far.

First Impression

The Elzetta ZFL-M60 is flat-out one of the most well-constructed flashlights we have ever seen. Every aspect of the anodized aluminum body is perfectly machined, from the head module and tail cap grooves, to the knurling. Quite a few of the other flashlights we have seen and own do come close, but fall short when you pay attention to finer design details.

The ZFL-M60 is designed as a tactical and weapons light, but it is very well suited as an everyday flashlight as well.

Elzetta with Malkoff Devices LED Light Output

How do I say this nicely? The ZLF-M60 beats the juice out of many other tactical flashlights in its price range. Even Surefire’s newer G2X and 6PX tactical flashlights (including variants) just cannot compare as the Elzetta’s Malkoff-made LED module throws a much brighter and whiter light.

The Coast A25 LED flashlight that we reviewed the other day does best the Elzetta in terms of brightness. However, the A25 is larger, heavier, and is rated as water-resistant whereas the ZFL-M60 is completely sealed and waterproof.

Low-light mode

Our review sample has two brightness modes, low and high intensity, that are selected via the rotary tail cap switch. A momentary and latching push-button switch turns on the flashlight, and the tail cap is rotated to select the intensity setting. Fully-tightened/clockwise sets the light to maximum output mode, and a slight counter-clockwise twist sets the flashlight to low-output mode.

High-output mode

Maximum output is rated at 235 lumens and low-intensity output at 15 lumens, which is usable for casual lighting needs. Runtime is 1.5 hours at full output, or 40 hours at low.

Impact-Resistance, Toughness, Durability

Did you catch the video of the Elzetta representative hammering a nail with one of these flashlights? That’s a pretty good example of how impact-resistant these flashlights are.

Thus far we have dropped (thrown) the flashlight, submerged it in water, and shook it up real good. Absolutely nothing we tried seemed to have affected the ZFL-M60! All we’ve done was tire ourselves out, so we will be heading back to the drawing board to plan another series of tests.

Made in USA!

That’s right, the Elzetta ZFL-M60 tactical LED flashlight is made in the USA! This does mean that the price of the ZFL-M60 will be higher than similar imported aluminum-bodied flashlights, but it’s worth it. As mentioned, the machining of the flashlight body is exceptional, and we could not find any flaws in the grooves, threads, knurling, body rings, or crenelated bezel.

Conclusion

The Elzetta ZFL-M60 is a rock-solid tactical flashlight. Elzetta claims that it is the toughest flashlight on the market, and from what we have seen, we believe this 100%. It is worth mentioning that we don’t usually use flashlights in life-or-death situations, especially not in combat where a weapons light may be used. Even so, we don’t recall ever seeing as well-built a flashlight as the Elzetta.

We absolutely loved the Elzetta, and found it to be an incredibly well designed flashlight. The LED module is from Malkoff Devices, which has a phenomenal reputation for quality. You cannot go wrong with the Elzetta ZFL-M60 – we highly recommend it!

These flashlights start at about $155. The model we reviewed is the CS2D versiom – crenelated bezel, 2-cell body, with high/low clicky tailcap, and is priced at $180.

Product and purchase information via Elzetta

Our only complaint (if you can even call it that) is a very minor one. Somehow the flashlight was turned on inside its packaging due to rough handling by the USPS, almost completely depleting the batteries. The click switch is springy and does require some force to depress, so the flashlight won’t likely turn on accidentally when carried in a case or holster, or even in a bag. But, it has happened, and can potentially happen again. The size of the click switch is comfortable, so our preferred solution for rough transport will be to unscrew the tail cap a bit until it disengages, just in case.

One thing to note is that the LED beam focus is of the spotlight illumination type – there is no floodlight mode. The same is true for all flashlights of this nature.

Thank you to Elzetta for providing the sample for this review unconditionally. Review samples are typically returned, donated, or in some cases retained for further testing or benchmark and comparison purposes.