I haven't seen any of the switches you want. What about using one of the multiple led drivers floating around? I see them on several chinese sites. DX, KD, etc. Any of them work for 5 XM-Ls?
Yes, but not boost drivers that'll run multiples in series, and I ain't wasting time or parts on this one to change the battery layout. As you know from yours, due to the, ahem, 'quality issues' here I think it's best to do this one quick and dirty and if it lets the magic smoke out, it will be a fitting end to the whole mess.
I have another host bigger than the SRK on the way for the triple MT-G2 setup, hopefully that one will be more worthy of the high-dollar parts.
nice nice!
Behold! A driver has been chosen, from the junk box! (with p60 pill for scale)
Original momentary switch to control the little micro-relay - press and hold for ON & release for OFF, as this is not the kind of setup you would want to leave switched on for any length of time anyway. The relay will activate at least as low as 2.8v, I don't know how much lower than that it will go. I might add a resistor inline to disable the relay at around 3v to prevent overdischarge. It may also need a diode to protect against spikes when the relay disengages, though it could already have one inside, I will have to crack it open and check.
I think you have invented The Mad King! J) …or something like that.
I wonder how many minutes it can be on before its too warm to comfortably hold.
Hot or not! I really like it! 
With the XREs the necessary wire clearance was built in to the design of those LEDs and their boards, with XMLs it had to have this relief cut for clearance. As it is in that pic it's technically deep enough, but just barely (I'm using 22AWG silicone wire on everything from now on, the teflon stuff is just too hard to work with, it likes to rip off solder pads and generally be a pain in the ass). I'll probably take another cut of something like .060-.080" in that same pattern before switching to the smaller bit and removing the bridges between holes (the one that cuts fast enough to not drive me crazy is too big to fit inbetween).
Ohhh what can be done with proper tools, I yearn to be handy!!
Proper tools? LOL Not hardly, just a $130 Chinese SKIL drill press, and an assortment of Dremel carbide bits! One of these days I will pick up a small cross slide vise, as it is now I have to slide the parts around with my bare hands. Knock on wood, haven't lost a finger yet, but the parts do sometimes get snagged by the bit and flung to the other side of the room.
Nice machine work and pictures. I like the last picture. Great idea one how to precision cut the reliefs.
Plans are to cut out the middle of the stock threaded aluminum plate/pill thing, leaving just the threads and a small ~1/8" wide shelf around the ID, and make two copper plates to sandwich it... top plate will be bigger than the thread OD to seat on the lip inside the head, bottom one will be smaller than the threads so it can pass through. They'll be clamped, then soldered together. Should be just as good at handling the heat yet still be removable. It'll be like a big flat C8 pill, basically.
But I don't have any suitable copper plate on hand currently, I have to get some before much of anything else can happen.
Or... I could use aluminum, and TIG it...
Thats fantastic work there comfychair. Very creative. Do you have a problem with the chuck falling out of the taper in the spindle?
No it's a cheapie, the spindle isn't removable and has a JT33 male taper on the bottom. The chuck is garbage, jaws aren't parallel... major PITA to get the tools chucked up so they spin true. I'm intending to get me one-a them thar fancy ball bearing keyless jobbies, those make life so much nicer. :bigsmile:
This makes your effort even better. You are seriously showing us all how top class work can be achieved with the wrong tools, like a couple off other people here. Thanks. It makes us all think a little harder.
I dont know whats wrong with the picture. Put me out of suspense and tell me. All I see is a lot off ingenious hard work in a fantastic mod.
Does this help any? :p
Nup. I’ll stick to what I said. Have you got a plan off attack to polish the reflectors?
Wait, so 5 LED SkyRay Kings aren't out of the ordinary? :_(
Reflector polishing isn't hard, just horribly tedious and boring. I can't even attempt it if I'm the least bit sleepy or I get half-hypnotized and start to nod off which is not good when you're holding a Dremel.
I didn't mess up the plating on accident, there was horrible casting flash all over, it was a mess to begin with.
Yep very unusual. But I could see nothing inordinary with what you have achieved. Top job. 