Ok, I took some time to find out if the Driver would really fit the AAA light. Here's some photos:
Here's all the pieces.
I bored the head with a 1/2" drill and then used my rotary tool to just take a few more thousandths out.
This is the depth from the top edge of the head, that I bored out. 11.97mm, call it 12mm.
The driver is 4.64mm thich.
The modified Reflector measures 5.03mm and that only leaves me with 2.3mm for the Emitter and Star! Not a lot of room and it's going to get hot fast! I cut the fins off the reflector and used a coarse sandpaper till I cut off all of the base of the reflector. When you sand it down, you open it up to the major diameter in the bottom. Plenty big enough hole for an XM-L.
The AAA body had a non-threaded taper on the top edge. By eliminating that taper I gained over 1mm and that lets the body screw in further. I am at 1-1/2 turns in, so it should work well. The top edge now works as the ground contact to the board. The outer ground ring on the board fits perfectly against it.
Here's the board in place. I did have to sand with fine paper, all around the edge of it, to clean it up and remove just a few thousandths.
Here's the reflector in place and you can see there is not a lot of room here. I think an XM-L AAA Maglite is stretching things a bit. I will be using a thin copper pad behind the star and a copper sleeve between the star and driver, so it should conduct some heat to the head itself.
More to come, later..............................
Ok, so the driver is history (toast is more appropriate), and this is now a DD light. Here's a couple photos.
I used the shell of the driver for the contact plate.
It's just a normal copper pill, like I have shown in the videos before. The reflector is OP.
100W (rated 450lumen, when did they start rating light bulbs in lumens?), for a comparison.
AAA light with 2Alkaline batteries direct drive.
White door, the only thing white in the garage. The LED is a T5 3C 5000k, from Illumination Supply.
I'm done with this one. Next is the AA light.