Unlike with flashlights () it felt a bit uncomfortable opening up a brand new power supply, but here are 4 pictures (I give links because they are quite big and I don't want to ruin people's page loading time):
I am not an electronics guy, so although I have a general idea of what is going on in there, I haven't got a clue if what I see is good or not, or if these pictures even show anything relevant to compare it to other power supplies.
I was merely curious what you had done to the light to get that kind of output. I have a lightbox given to me by friends and calibrated by them with a rather extensive base of lights. It is fairly difficult to get true Out the Front readings such as that.
That being said, I built a Convoy S6 today using the new BLF 17mm DD pcb and FET and with really good cells I am getting 6.95A at the tail and 1377 lumens at start, with 1211 lumens at 30 seconds Out the Front. This is, I believe, an XM-L2 T6 3C or 3D emitter on a SinkPAD.
I also tweaked a TangsFire TS2010 to get 5.46A from a Sony C4 18650 for 1656 lumens on start up and 1556 at 30 seconds. This is an XM-L2 U2 1A emitter, still domed and mounted on a Noctigon.
The light in my avatar is a Solarforce M8, with 8 ounces of copper for it’s heart (made by fellow member Bucket), with the MT-G2 on a Noctigon and reflowed directly to the copper pill. It makes over 4200 lumens at start up, and 3600+ at 30 seconds, creating quite a lot of heat in the process! It too is utilizing an FET modified driver, pulling 10.81A at the tail.
Fun stuff!
Good luck figuring out how to make these issues universal, as the variables are quite troublesome.
djozz, that looks like a very robust power supply (not that I know much about these things but still) Enjoy it man!