Kind of time consuming to make an ordinary 20mm star fit in a pill made for a 16mm round emitter board.
Next time I'll have the flashlight home before I buy new emitters so I know what I need. 
Yup. Been there. And it really doesn't have to be that big difference to chew up your precious time and way too many beers. It recently took me couple of hours and fiveish beers to put a 16mm board into a 16mm pill. Except the board was not 16mm, it was 16,5mm. And the pill was not 16mm, it was 15,7mm...
Is that middle one a neutral XML btw?
a small belt sander makes that so much easier. I guess a 1x42 belt sander is a bit expensive if all you are doing is cutting down an emitter or two though. I'd check and see what woodworking friend might have one.
Not only is it a time consuming pain in the @ss, but one slip and your nice new emitter is scarred for life. Done that more than once.
So true :)
i had one as i was just finishing grinding it AND pop ! - took 30mins to find it
after orientating it took a blow torch to the bottom and wal-la! back into place EXCEPT the top terminals rolled up due to the grinding LOL
currently in a SacredFire NF-009 working fine 
never to be desoldered again
Yeah, I used a small Dremel grinding tool and it took about 2 hours to sand it down to desired size. I'm not doing that again any time soon. I used the light for about 1 hour this night and it worked perfect so no greater damage to the led even though I lost grip of it two times and sent it on a flying trip.
Be-Seen Triker: I actually had that in mind so before soldering the wires I tested the connectivity with my DMM and made sure there wasn't any apparent connection problem. Not bulletproof but as you mentioned, it's worth noting that you should have it in mind.
On a side note, warm white X-ML rocks!
Reducing my 10mm XM-L board to 8mm wasnt too much fun either... I thought I would use a file to keep the bottom nice and clean, but by the second stroke the emitter met the filing surface of my relatively new sharp file.
Much Joy!
As a large surface emitter, going to a floody reflector, its not a problem beam wise, but its not a happy moment! haha.
Haha, yeah I know the feeling. When my emitter flew trough the kitchen slow motion kicked in and didn't end until the emitter landed safely on a plant. Lucky me.
Impressive work to sand down a 10mm board, not much to hold on to without crushing the emitter, I had big problems holding the 20mm star.
So... what're you building that needs an 8mm xm-l? And where did you find a 10440 that can power it? :)
I was able to find _one_ neutral white xm-l on a 16mm board, so no filing for my project! Unfortunately he said he had no idea when he could get more of them, so if I find any other projects, cool white or having to file...
--Bushytails
Well, it takes a couple of hours to file down the board but your going to use the light for many more. I say it's worth it just to get rid of the nasty "white" (i.e. blue) tints.
You know I'm right. 
ROFL Volk- true as long as the led doesnt fly off
How about a list of best places to get different size XMLs
this is the cheapest presoldered T6 i can find
i need a 14mm board cheapest i can find here
t6 16mm $7 USD
t6 14mm $10.75 USD
anyone know where an 8mm presoldered one is for sale or anything cheaper than the above