Very awesome. Two powerhouse modders at work.
11-08-14 More progress in the OP.
Pretty cool. I have some of those charge modules on the way myself. Great file work as always.
Congratulations! Great job 
thanks for sharing 
Fibre what? Yes I need pics to understand it, thanks. I'm a bit bedazzled to be honest. 
Finished the brass cover for the optics.
I'm done for the night. Going to go sit down and relax.
Fiber who?
Seriously O.L. somebody at Maglight should put you on payroll as a Consultant, Chief Designer, something ....
There sales would explode, (in a good way) .
Thanks for sharing, looks AMAZING.
Why is the cover plate looking immaculate? It should be full of crease marks and an odd looking shape. Are you sure you dont have a laser cutter out back hiding with your elves? So the light is going to have fibre optic feelers. Neat. 
We don’t always get the luxury of a lot of new & different stuff around BLF. This project is refreshing!
You can’t really do UV behind plastic windows or TIR lenses as I understand it. You must use a reflector and a glass window.
hmmm. You say the light is going in a specific vehicle, my first thought was a charger. Am I right?
Nope!
Amazing work!!!
OL, can you tell which optic are you using for the nichia?
Thanks!
Amazing work!
Out of curiosity, what happens if the user plugs in the module to the USB and turns the light on? Will that be ok for the charge board? Will it be the 1 amp from the charger plus whatever the battery gives to power a given mode? And if less than 1 amp then the battery will still charge? If so, this will take the title of coolest USB-powerable light ever. Slap that onto a car charger and you can throw a disco party everywhere you go.
Also, do some nichias have that little square on the base board because 1 of the LEDs looks like it has it while the other 2 don’t in the LEDs shot.
I will leave that to rockhound42 if he wishes to.
I do not know for sure. I would think that the driver would pull from both sources, but it would not pull any more than it normally would. The driver is asking for xxx amps and whatever the power source, it would only take what it wants, but as to problems with both sources on at the same time, I just do not know. Never thought of it really.
All the Nichias are the same. Just the angle of the photo that hides the black spot.
The optics for the Nichias are from CNQG. They are 15 degree, 20mm around and designed for XM-L, but the beam with Nichia looks fine. I tested them out before hand.
Rotary tool, Dremel #115 bit and plenty of patience, opening the holes up and then fine tuning them several times. They are not perfectly round, as I did them by eye and checking by holding the plate over the lens, but they came out fairly close. Not perfect for sure and not as accurate as a machine would make. None of this is that accurate. I’m a perfectionist, that’s why I am never satisfied with any of the builds I do, or anything at all, for that matter. I see they work, but I see all the faults. I think that’s why I try so hard, to try to bet that one perfect light. Of course that never happens, but it’s my challenge to myself.
Your skill and work always amazes me. great work & can’t wait to see this one completed with beamshots.
The light will eventually be going in a 1998 Land Rover Defender 50th Anniversary V8, that is a little different from how it left the showroom.
But looking at how it’s turning out I don’t think many of my other lights are going to get that much use after it arrives this side of the pond.