Today was multiple facepalm day, my modding efforts were only partly successful.
My lens from KD arrived, it's ok, but not perfect. There is definitely some coating on it, but it doesn't have that purple tint to it when you look at it at an angle. The coating also doesn't reach all the way to the edge but stops just short of it. I'm going to keep it anyway because it's 300% better than my old scratched plastic lens.
After taking apart the light, I desoldered the led and took the driver out. First thing I found out was that the 1206 sized resistor is exactly so big that it covers up the solder pads. I tried to solder it a little bit to the side of its place on the pcb. I'm pretty experienced at soldering, but I never touched smd parts before. The result looked a little bit jury-rigged, but I thought it would be ok.
Removing the ano was easy, sanding and polishing the pill to a shiny surface took a little bit more time.
Next thing I noticed, I bought an XR-E R2 on a 20mm star that was too big to fit in the pill. So out comes my proxxon (something like a german dremel) and I began to sand away the edges of the star. Took a little time, but it turned out good. When I out the star in the pill, I noticed I had sanded away the + and - markings, but I could figure it out by looking at another star and the positions of the wires on the die.
So I put thermal grease on, soldered the wires to the star and assembled the light. Then I noticed the plastic led cover wouldn't fit anymore due to the big star. Luckily I had some thin XR-E covers from IOS, that saved me the time to make a spacer myself.
At least it worked right from the start. I have no ways to measure brightness, but I thought it was significantly brighter that before. Took it outside tonight, and man, it shines.
But next mode memory was still there, bummer. Think I'll take it apart again and have a closer look at the resistor.
Moral of the story, do what Tom E did and buy a 0805 size resistor