I build the original switch back in an made some tests. And as i expected the internal resistance is huge. After a few minutes at 5 amps the tailcap is getting warm (but not from the leds, the contact resistance in the tailcap is producing heat). But if you see the small weak contact point from the switch and the host it is self explaining why. The new design will help with that. More contact area and a screw that is pressing the pcb against the Aluminium ring in the host.
The tripple reflector with new Aluminium ring to fit in the head
The shelf is now nearly flat. The JB Weld + a lot of fine copper powder worked well but was a pain to grind!
Grinded down the Aluminium ring from the Momentary switch to make place for the new driver.
Both reflectors inside the head. On the left side there is not much left to do only put in the MC-E on the right side i have to make a 8mm thick spacer to make the tripple reflector fit (the Aluminium ring to make it wide enough fits perfect).
The beginning of a new switch PCB (because i do not have any etching solution left i decided to grind the copper of the board.
oh wow, looks very nice
I did not realize there was a major mod going on here. Nice work so far. :+1:
“”Probe shiny”“:https://www.aliexpress.com/item/Super-3000Lumen-5-Modes-Zoomable-CREE-XM-L-T6-LED-26650-Flashlight-Focus-Lamp-170129/32789673583.html on Aliexpress, 18650 (not 26650) USB rechargeable flashlight with powerbank.
One step closer to get the UV tripple led spacer ready (core is 21mmx8 but i need 21x9 so i have to add another 1mm). All done by hand or my dremel. So it took a little bit longer than it would on a late 
Wow, such work going into this. It’s going to be a very special light when finished! :+1:
I like the work often much more than the finished product. Some small things can take hours and hours. Like this spacer when its done. Today new switches for my solder heat plate arrived. Now everything is here i can complete it (aslong nothing else burnes up). The first 12V 180W china PSU went up in smoke (at 120W load). Now a 450W PC PSU is in use. A little bit modding was needed, but i have a good stock on old PC PSUs so it cost me nothing. Only a bit of work. I think in the next few days i will upload a few pics (when its ready).