I don’t think comychair likes my idea. :_(
Not that at all, it's Ohm's Law and thermodynamics that don't like using the springs. I'm just the messenger. :bigsmile:
There are many different kinds of conductive adhesives. You could try this place and ask for a free sample.
Ok I like the Arctic Alumina Adhesive idea, which I can buy @ mtnelectronics. Or 18sixfifty's idea above... It's quick and may be a great solution. I'll have to try it. If it doesn't work as expected I'll have to look at the other ideas.
The negative spring reaches and touches the aluminum (AL) piece when you put it all back together. But if I made it permanently attached to the AL piece, then the light will be more reliable.
yeah I cheated and called all you Smart Tech. builders in here. thanks for all the responses.
go to bed already 
I even PM'ed Old-Lumens - I guess he's asleep. 
I'd simply wrap it in copper tape. When shoved in tightly and done right it becomes a very solid connection .
Maybe you didn’t get the PM, I don’t know, but I did reply and here it is. First of all, it’s about impossible for me to see what’s going on with the problem, when the light is there with you, not here with me, but I would hazard a guess that it’s too late to do anything correct on the light now, since that aluminum core has been cut down. What should have happened was to measure the depth of the drop in and cut the aluminum so that it would overlap the brass of the drop in, even if the aluminum had to be opened up inside to do it.
For what you got now, just go with copper tape. Not much reason to do anything else now and drop the outer spring. If you feel that will not work, solder a wire to the brass pill and run it to the aluminum insert and drill a hole in the aluminum insert, put the wire in from the inside to the outside. Solder on the inside so it can't come out, then solder from the outside, till it can't go in and sand it smooth to the aluminum's outer wall. Or drill and tap a hole and use a screw to hole the wire in there.
Like I say, without seeing it in person, most of what we say is probably meaningless.