Insight VLI

The Insight VLI (Visible Light Illuminator) is a rail mounted weaponlight produced and used from the late 90’s to early 2000’s. It is relatively large by modern standards, but was Insight’s attempt to create a rugged and flexibly mounted light for the rifleman of the time.

A typical kit consists of the light, a remote switch, several lens caps, and a manual+bag.

While I would love to display a patent, I am unable to find one. It could very well be that the design is so simple, so conventional, that nothing about it could be patented.
It was also branded and sold through Streamlight quasi-commercially, during the same years. Streamlight stopped advertising them after May of 2000.

As far as VLI-001 vs -002, I have not been able to discover anything illuminating, and it could very well be a case of ‘minor revision made before mass production and deployment’, meaning the -001 might as well barely exist. For what it’s worth, the two versions are referred to interchangeably throughout most documentation, official and unofficial. There does appear to be an -001C version, but only on paper.

These devices are marked under the rail attachment clamp.
I have not been able to confidently decipher the meaning, but the second half *could* indicate January of 1999 production. Just a guess.

The labels on the devices clarify ‘DO NOT STARE INTO LIGHT BEAM’, but I wouldn’t worry too much. The output of the device is 115 lumens with Lithium, and 90 lumens with Alkaline, using an incandescent bulb.

If one wishes to upgrade their device, they can acquire an LED upgrade kit from Lumens Factory for ~$50.

The VLI was made with many lens covers and angle-adjusting diffusers, and Insight also made blue, red and infrared filters. As a fun fact, the manual clarifies that if you are using the opaque filter, ensure the switch is not left on, or the cover may melt.
Production was seemingly outsourced to Butler Creek (a very big name in lens covers, if such a thing exists) as evidenced by the barely visible markings on the inside.

These can accept either 3x DL 123’s, or 6x AA’s. The battery cap module is also the lens module, seems quite proprietary, and is marked VLI-100

As far as activation there are three options. One can use it with a remote switch by removing the small plug on the lower of the two protrusions on the rear face, or you can remove the top plug, which allows you to twist the activation lever to either constant on or momentary on, depending on which direction you twist, similar to a TLR-1.

I have generated a moderately detailed .step file of the overall geometry, which you can feel free to use for any creative endeavors.

Download 3D CAD [4mb]

I have poorly photo’ed the manual, which can be downloaded below.

Download Manual PDF [5mb]

These were somewhat common during their time of use, but didn’t stay the light of choice for long. Per 2000/2005 documentation, it was heavily recommended that each Marine company (234 people, give or take) that might engage in night time combat (which is most of them) be supplied with 134 of these devices.

Initially, the ‘Night Warrior Handbook’ by the US Fifth Marines reads “Every rifle in the company needs white light capability.” which is an understandable sentiment in the context of MOUT. However, perception of the device was apparently mixed, as it later reads “VLI is a good idea poorly executed – too big, too heavy, and it needs too many batteries. We did not take a single one into Iraq.”

Such perception was commonplace. Take a trip down old-internet lane, as I share comments from this 2002 forum discussion…

“P.O.S. !!!
Save your money. ”

“I’ve looked at the VLI also It’s neat and has the Insight name ,but for the price i think an M900A from surefire with the grip for $400 is a much better value.“

“The VLI is noted by Operators to leak, to have bad switching problems, short bulb life, weak attachment to weapon… etc
I believe that a dual battery model was asked for. The difference in properties between the Alk AAs and the Lithium 123As is significant. It appears that the bulb just wasn’t up for it.
The SureFire WeaponLights such as the M95, M96 & M900A are being used because the VLI fails.“

“The VLI tac light was great in concept, but proved to be un-reliable, weak in construction, and terrible light out put. Guys had to suffer through using those things for way too long. The switches were not user friendly, the unit could not get rained on without shorting out, and once the mount broke, you were screwed. A lot of guys started using their 6P’s and using zip ties to mount them.
Oh, and it was a sure-fire knock off that got the contract due to the “good ol boy” network.“

The device can be seen in the famous SOPMOD accessory kit poster, but by the Block 1, it was replaced by the Surefire ‘Visible Bright Light II’.

Most interestingly from the forum crawling, there appears to be some legal aspects to make a note of. I have not been able to find more information on the following claim however.

“No longer available to the commercial(or LE market). They infringed on somebody’s design for the dual battery thing and took it off the market to avoid legal problems. They now only sell it to the military.

The military appears to have begun phasing them out in ~2002 with Surefire M962C style lights, and then later to Insight M3/M6 form factor lights (which were around in 2002 but I suppose they wanted to try out Surefire first). By 2003, these were considered somewhat obsolete even on the civilian market, barely mentioned in advertisements or forum posts.

Another fun fact, Insight attempted to sue Surefire over the mounting design of the M3 style light in 2004.

Within the military sphere at time of use, these cost around $180 per unit.
Currently on the second hand market, price varies widely from $50 to $250 depending on condition and completeness.

MISC DATA

NSN	5855-01-448-5464
NSN Creation	September 1997
Weight	7.2 oz
Dims (Including Mount) (mm)	166.5 L, 45 H, 42.5 W
Diameter, Main Tube (mm)	37.25

Despite its age and shortcomings, it certainly scratches the itch for accessorizing an early 2000’s A4.