I just got a Zebralight SC600Mk 2 and found that the battery tube was extremely snug with my Panasonic 18650 3400mAh battery. So snug that I had to remove the label and coat the battery in graphite! The only way to get the battery out is to shake it violently. Light works great but SHEESH!
Has anyone else seen this? Is this a manufacturing defect?
I believe you can get a 17650 or even a 16650 if needed
Or ream out the battery tube
does any other battery besides that one fit snugly?
No it's not a defect. It's the way the Chinese use a ruler.
contact zebralight or the store you bought it from
I assume a protected cell? Remember, Panasonic doesn't make them. All protection is aftermarket and therefore varies with each protection circuit and subsequent shrink wrap.
But then again, it even happens with AA's occasionally.
The Zebralight is supposed to be used with a non protected battery. Stick a protected one in there and you may never get it out. You don’t need protected in the Zebra, the driver has low battery warning and protection.
There’s a looong thread about this over at CPF. I’m not going to link to it, but it’s worth a look and easy to find.
Long story short, the ZL battery tube is fine as long as you don’t insist on using the absolute largest cell out there.
I would consider it a defect. Regardless of what Zebralight says.
Design flaw maybe? Not a defect. A defect is if one light is like that, but they’re all like that.
And even then, it’s only the thickly wrapped 3400’s that have problems. Just don’t use a thickly wrapped 3400 and it’s fine.
True, design flaw is the appropriate term but “defect” is, in a way, more insulting so I like that. Its not hard to measure and add a half mm.
:bigsmile:
But from a design stand point, you would have to consider both ends of the user spectrum. If they added yet another half mm to the battery tube, the tube would be that much more oversized for smaller unprotected cells. I don’t know if you’ve used a 2900 or smaller unprotected cell in a big battery tube, but man, it’s kind of annoying how much the cell moves around and rattles. That’s probably not a problem for most people, but for a headlamp or a bike light, it can be an issue.
With my SC600II XML U2 a protected Panny 3400 NCRB was extremely tight as you described (so I used a NCRA instead), when I got the newest SC600II L2 (darker ano) an NCRB fit in it no problems.
I just fold a small piece of paper and slide it in with the battery.
A half mm too big is not a problem IMHO. Only too small is.
A defect could effect a whole run of lights. We would need to know the internal diameter specified in the design files.
Cells have been rattling in flashlight tubes for many decades. If it bothers you, cut a piece of a cardboard tube from a roll of paper towels or similar and line the tube, no rattle. It's very hard to fix 'too tight'.
no no no…not a defect or design flaw…it’s a “feature” 
Well…it is if it’s in the M$ Windows world 
Thank you Mr “Devils Advocate”. That idea was already introduced.
The manufacturer could include a thick adhesive sticker either already applied inside the battery tube or separately for the user to apply. Remove or don’t apply sticker if you only use slim batteries.
Simple and everyone is happy.
I used some double sided “removable” poster tape to hold the paper spacer in one of my lights. Stays put, no losing it or fiddling around with it when changing batteries.
Not that simple. Not everyone uses thickly wrapped 3400s. Whether it’s a ZL or certain Convoy hosts, a lot of people use smaller cells in smaller hosts and are happy. We just don’t hear as much from them because they have nothing to complain about and therefore do not post.
So why should those people have to compromise and use spacers and such just so that the people who insist on using cheaply wrapped, too-thick 3400’s can have a better fit?
Why are you people arguing about this? Buy it if you like it, don’t buy it if you don’t, it’s simple. If you think Zebralight tricked you, punish them with your money by not buying from them. There are plenty of flashlights out there for everybody.
How is a sticker harming you? Making you feel like your compromising?
Even bare 3400s are thick compared to others. Protection just adds a bit more.