Stock lanyard from a cheap XML light. Note the fraying (new light, barely used).
Weakest part of the cord (where it was cut and melted together) is exposed to the most stress due to this design.
The smaller part ripped after a few seconds with a 12.5 kg load (regular paracord was used to attach it to the lanyard). For comparison, micro paracord is rated at 85 pound / ~40kg. Chances are it would have ripped under a load of <10kg at longer exposure.
The smaller cord also cut partially through the larger one.
Same design on lanyard of a more expensive light (SA22, ~$25). Haven’t tested this one yet, it’s not much thicker.
If you want to keep the general design or if the lanyard hole on a particular light is too small for the main cord you can join the cords by using a double sheet bend a double simple simon knot https://www.youtube.com/watch?v=k04ksR3i7zA for example. Use a double fisherman’s knot to close the loop on the smaller cord - it’s >30% stronger than a regular overhand bend.
Not any better on expensive lights in my experience and don’t trust the metal carabiner’s/spring clips that some lights come with, they look strong but the metal is some sort of poorly cast pot metal, nearly lost a brand new $300 light down into the abyss when the supplied carabiner on the shoulder strap snapped, was only luck I felt the strap sliding over my shoulder while taking photos and I just grabbed the end before it was gone
Used a tiny round spring clip, and then a regular sized round spring clip so my Nitecore EA41 could still tail stand. Wifey weaved a new para-cord lanyard black… meh maybe 3 - 4’ but looks cool and can use in emergency… I’ll try an post a pic.
To get through those wee holes, if you can find an old set of mini-blinds, the cord in them is awesome for the job. You can dye it any color you like, or mark it with a Sharpie (before you tie it) for short pieces.
No mini-blinds? The local hardware store might have “mini-blind repair cord”, but that’s likely to be too big. OTOH, they also should have “Brickmason Line” (braided if you can get it, but even twisted will do) which will also serve you well.
Too lazy to learn how to braid paracord. Too old to want skeletons, monkey fists and dragons lookin’ at me from my lanyard. Too sceptical to use those kite string things that come with cheap lights.
Do need a good source of plain old sturdy lanyards for my knives and lights. The fewer hooks, rings and attachment thingies the better. Color choices optional.
Any good sources out there (especialy BLF sponsors or members)?
The fraying on the stock lanyard is inconsequential, they fail because the fishing line inside the frayed area breaks.
I gave up after a few breaks, i now assume all chinese lanyards are junk.
I have some paracord, i am happy to learn about more knots like the ones posted since i currently just tie the ends.
Normally I gently take them off and put them in a zip-lock bag I have full of lanyards, but it’s already full of lanyards. Today I went to gently take one off, thought of that bag full of lanyards, flicked my Delica open, and just cut the sucker off and put it in the circular file.
i never use any of the stock lanyards that come with lights, not even the good ones. I always make my own from 550 paracord.
Even my tiny Thrunite Ti & Tank E09 has a small paracord lanyard.
I use clips from the fishing display at Walmart. I also use nitrile o-rings. I am not sure of the o-rings’ reliability, but they are nice and flexible. Silicone o-rings broke on me.
A double sheet bend seems correct. I don’t know why you don’t use it in both places.
Nice knot work on your site.
a double simple simon knot https://www.youtube.com/watch?v=k04ksR3i7zA for example. Use a double fisherman’s knot 
to close the loop on the smaller cord - it’s >30% stronger than a regular overhand bend.
