I checked the first concept, and it looks perfect!
The light gets a tactical switch. Other components for the self-made host are already ordered.
The length will still decrease by a few millimeters later in the build. In general, the design will change a lot later on. Next week I will proceed with the design, as soon the other components will arrive.
There is a problem in the build - the tolerances of these cheap brass fittings and threads are way too high. The bezel sits crooked on the rest of the tube, which is clearly visible and it would be also problematic to build the LEDs and the optic in.
I looked for some alternative pieces, which are ordered. I will also look for better pieces in another hardware store…
At least the driver, the LEDs, the board and the optics are also ordered
Plumbing fittings are made with a tapered cut thread on purpose. When screwed together the threads jam together and that helps to make a tight seal. I haven’t worked with enough threaded pipe to know if there are some brands or sources that would be better. There are some fittings with the same diameter and thread pitch used in the electrical trade that have no taper. But no brass or copper that I know of. Sorry, but I have no other help to offer.
I have fittings without taper. Here in Germany they are also available in brass. The problem is that the threads are not cut exactly straight. For water pipe installation no problem, but for this purpose. There will also be major differences between manufacturers in terms of tolerances. Branded fittings (not the cheap ones from the hardware store) generally seem to be better. I ordered fittings from another manufacturer. The threads of the bezel itself seems to be straight cut.
Allow me to modify my posting… In the US and Canada there are different types of threads used for different types of fittings.
There are “pipe fittings” sold as NPT or NPS. NPT and NPS are not used in Europe and EU fittings are not used in US/Canada.
NPT = National Pipe Taper and NPS = National Pipe Straight.
NPT are the common fittings such as where a length of pipe is joined to another pipe with a straight or angled coupler or tee.
MIP and FIP terms are also used… same thread configuration as NPT. MIP = Male Iron Pipe, and FIP = Female Iron Pipe.
NPS fittings are normally used where O-rings or gaskets are used for sealing.
Then there are fittings that are “Compression fittings”. These are used to join rigid pipes (iron, brass, PVC, CPVC) to tubing that could be copper or plastic of some kind. The compression threaded part is a different thread and will not mate with other pipe threads.
That sounds frustrating. Have you considered getting a tap and die to cut your own threads? Doing that can bring its own challenges but could also give you more options.
4 this project. I always admired your knowledge 
