Thanks for the input. Thats kinda what Iāve been thinking, CRX. As far as materials, Iām thinking of ordering some copper strips online. Probably something like 2mm x 15mm for the inner strip and 1mm x 18mm for the outer strip.
I wanted to get a feel for size and fitment before I started ordering strips of metal and PCBs. So I decided to make a scale mock-up.
I used Fusion360 and my 3D printer to make the model. But no 3D parts will be used in the actual build of the flashlight.
Legend:
- Black: outer brass trim (I could find brass more readily than copper in the right size)
- Blue: inner brass strip for making a ridge to mount pieces to
- White, solid: base plate, likely smoked translucent acrylic
- White, holes: main PCB with most circuitry
- Gold: PCB with 8x 2835 LEDs (rated at 150mA, 4000K)
Shown with the battery, switch, and the Qi charging coil
Anything that would show the scale?
The mockup looks really good. Is the switch about 5mm square?
Here it is next to a 18650 and Tool AA for scale. The switch is 12mm square with a ~7mm diameter button.
Small. 
Lookin good gchart
Among other things (see the OP), PCBs have been created and ordered using Oshparkās After Dark service (black substrate with clear mask).
After dark for black magic?
They look good. 
Black Magic, you know it!
I recently tried the After Dark for some tailcaps and they came out great. To take full advantage of the service, you need to tailor your design for it so that the traces look good (and potentially using copper for labels instead of silkscreen):
Iām somewhat jealous of your electronics skills 
And I of your metal work skills! Your creations are inspiring.
PCBs arrived today and they look great! I canāt wait to get them soldered up and tested.
Wow. Looking real good. It really is 50% black magic now. 
Haha, I see what you did there, Moose. 
Only 3 flashling pins? Are you going to use TinyAVR?
Yup! Itāll use an attiny412 running RampingIOS (D4 V2 UI). I originally hoped for getting Anduril on it, but I donāt think Iāll have time before the end of the contest to port Anduril over to the TinyAVR 1-series. Maybe afterwardsā¦ thatās what exposed pads are for, right?