Awesome - thank you very much. The links you provided also have the SMT pad, so I will try to incorporate the pads in future boards :bigsmile:
Will
The keystone suggested pad is .135 x .070. I use a smaller pad, however, as I had trouble with the test points floating around too much.
My pad is:
Copper: .120 x .055
Mask: .125 x .060
Paste: .105 x .040
PPtk
Wow, thanks again man - much appretiated sharing the smaller footprint data. I use spring-loaded pogo pins for programming my Atmel Tiny processors, and for testing some small boards, but these SMT test points will come super handy as they free your hands and allow for a good/solid connection while testing/trying things out 
Will
For sure, the solid connections and free hands are awesome. Once you start using these things, it gets addicting - I put them on every signal line I think I might ever need/want to probe. They’re small enough that it doesn’t usually have any real effect on board size, and they are so nice to have when you need them.
The pogo pins are what I always use for programming headers
Unless I’m really tight for board space, then I use a tag-connect layout
PPtk
Very cool. My programming setup is not fancy, but works well for the relatively low volume of my projects. Here I am programming a Tiny85:
And here is the programmed board on its battery carrier (cover off in picture, but bolted in place for end customer use). On this photo you can see the 7 test/program test points (some with silkscreen labels):
Will
Hi, does anybody know a free or shareware program for 3d design?
zeremefico,
Google Sketchup is actually not horrible for the cost of nothing…
http://sketchup.google.com/download/
If you design your module with that, it is great for me!
Nice project PilotPTK 
Sorry I haven’t quite been keeping up with this thread, but where are things at? Pilot, you have some already produced (fully assembled), are we just waiting to see what hosts will work well for it?
In terms of torches, yes - I still haven’t found a great host for it yet. A lot of people are inquiring about using these for non-torch applications though (bike-lights, off-road lights, you name it lights). I have some modules available right now for anyone who wants one - I haven’t announced major/general availability just yet because I’m still waiting for my shipment of U2 LEDs, and I don’t plan on running the big production run until I have everything (it costs big bucks to run on a U.S. production line for half a day).
Cool White T6 and Neutral T5 modules are available for purchase right now - I don’t have a lot of them though.
PPtk
There was discussion in this thread about using this module with a D Maglite. After seeing this thread (3D Magmule with triple Nichia 219s), I think it’s very feasible to fit this module and a heatsink into the top end of the Maglite with a bit of boring (just above the switch) The stock head could then be milled down, or a head like the one cut on the lathe in that thread could be used to hold the module and optics in place. If the momentary configuration is desired (I would want that), the module could be hard-wired and the stock switch could be converted to momentary action for mode changing (or the stock switch could just be replaced entirely). Along with cutting down the battery tube and either using 3 x 14500’s or have it bored for 3 x 18650’s, this could be a pretty compact powerhouse.
PPtk: Quick question - can the momentary switch be wired to pull up (to positive) instead of pull down (to negative)? That way the stock switch converted to momentary could work as-is.
Unfortunately, no. The switch must be wired between the Momentary Contact Input and Ground. It is pulled up on the circuit board, and the switch pulls it low to toggle an input. Pulling the Momentary Contact Input to Battery+ would be very bad, in fact.
PPtk
I want three with U2 binned XMLs. What is the price of one of these?
How much time is consumed in completing this extraordinary project?..I would be definitely learning something from you for sure !!! What are the prices?
My LED lights
Welcome to the site, tomloew!
Hi simplec6,
Cool white U2 Flux 1C Tint: $93.00 plus shipping
Since you’re in the U.S. - Priority Mail would be about 6 bucks for all three.
Ok, are the production version ready to ship just yet or are only the prototype boards finished so far?
Sorry I missed the price on the first page, maybe try getting that into the Original Post?
Sorry if this was discussed, but how hard or easy is this: “Max output: 3.2Amps (up to 5Amps with one resistor change)”? Would you change the resistor if we request?
I do have production versions ready, but I haven’t done a ‘big’ run of them (which is why I haven’t really advertised them as available very heavily). The reason is that I’m still waiting on the U2 Emitters that I ordered, and I want to run a big batch of Cool U2, Cool T6 and Neutral T5 all at once since more of the production cost is setup time than actual run time.
If you’re interested in a Neutral T5 or Cool T6, I have a few available.
PPtk