$200 for a Surefire shotgun forend? Fuk dat chit!
I had a serious need for a light on my 870. I explored a lot of options including a few other DIY options. Surefire forend was way too expensive and I didn't like the looks of it or how it placed the light far from the barrel axis. Mounting a G2 etc. on the mag tube would work, but it would pretty much just be a "constant-on" light due to location. I also considered adapting a pressure switch and cord to a light, but I couldn't find any pressure switches and had the problem of working in a constant-on switch along with the momentary pressure switch. Somewhere along the way, it came to me: Epoxy a G2 to an 870 forend! Due to your natural thumb position, you could use the light's built in momentary and constant on switches. The location would also put the light very close to the barrel axis and maintain a low profile.
What you need:
-Surefire G2
-JB weld (the overnight stuff, not 5min)
-an old 870 forend
- a touch of black spray paint
- a couple hours
Description of process below the pics.
Figure out your natural hand position and put the tailcap of the light juuuuust ahead of your thumb. This will alow you to hit the momentary tailcap switch without changing your grip. You then position the light in the built-in channel of the forend. I also added a thin scrap piece of aluminum behind the light to space it out just a tad. This made sure I hand ample clearance for the tailcap to turn. Fire up the epoxy and position your light. I used zip ties to hold it in place and put some hot glue OVER the epoxy to keep it from running while it dried. This was a key part of the process as I had JB weld trying to escape on me within a half minute or so. Initially, I oriented the light as close as possible to what I thought would be "sighted in" from previous trials, then I double checked after an hour of dry-time and re-adjusted slightly as the light had started to creep a little.
That's it. It's pretty straight forward, you just have to pay attention to how you align the light. Strength is NOT an issue, at least with the overnight JB-weld I used. You can swing the gun around by the light.
The gray stuff is 3M rubberized no-skid strips from the hardware store.
Props to Die-Tryin for hosting the photos.
EDIT: In case you are wondering, the light is attached via ~100 degrees of surface area.