The hole in the lens is fine. The dome of LED fits as it should. The lens is going to rest on the base of the LED and crush it there. It does not need to go around the whole LED including base/substrate.
Did you try to put your module in a light with the lens and bezel tight?
A previous version of this optic/board combination from KD (I have one) had a thinner 1mm thick MCPCB which was also not good: the holes were either too wide or the optic needed a bit sanded off the legs. I never bothered to find out what exactly was wrong because I never used it, but it clearly did not work off the shelf, something had to be fixed.
I fully agree with you 1stein. BanL, can you please try to source some Osram Ostar Projection Compact LE R Q8WP LEDs? These are very powerful red light LEDs.
I didn’t like it compared to the Carclo … it had a more visibly defined hot spot that had half ring artifacts around the spill… the Carclo has a smoother flood beam (depending on what type of LED used like dome vs de-domed) none to very little defined hot spot, better smoother flood spill the farther out the beam is shown, specially in the bigger heads like the X5, Convoy M1 and Surefire 6P… the Carclo in the FW3A was a smooth flood but gave a square beam profile, because the head is so small…and I had to turn the optic down so much to fit it…Carclo Quads don’t work real well in the FW3 size head…but the flood is smoother…
Does anyone know if the MCPCB it comes with works with both 6V and 12V? I want to use it in the Thrunite T1 which is confirmed to be 12V. There’s no option to choose 6V or 12V on the order page.