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Maglite 3-d batteries will not unscrew battery access cap. even used rubber for grip and use of channel lock pliers. all aluminum model.what else can I do to remove cap to access bat.

Can't unscrew battery cap on my 3-c or d batteries?

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I'm gonna catch it for this but this is how I did it. Corroded batteries in the cylinder will eat and seize the aluminum threads on the end cap and it's pretty much toast after that.

What I did was drill, yes drill a 0.125" (1/8") hole exactly .25" (1/4") above the seam between the end cap and the tube .0125" (1/8") into the tube. No more than that or you will jeopardize the integrity of the waterproof factor.

Drop one drop of a quality penetrating oil, or even diesel fuel, into the hole every hour while randomly tapping the tube with a metal object to create a vibration to help the penetrating oil travel throughout the threads and dislodge the corrosive hold on your end cap.

It might take a couple of days to loosen it up and try it with your channel-locks and a lined vice or strong wife. Just plan on gaining 1/32" movement and go back and forth until it gives up the grip. That process might take another day too. Keep adding the drop of penetrating oil along with the tapping religiously.

It WILL work provided your patience holds out. Don't force it... well, not too much anyway. You can actually save it this way.

Posted on Dec 21, 2016

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