Unreliable turn on from Zebralight H503c headlamp. RMA has the same problem. Contact issue?

Which paint?

I explored the flash/paint area near the contact with a pick tool and apparently it’s an optical illusion. Those seem to be indentations/holes/missing contact areas. Yeah, confused the heck out of me. In any case I’m not going to do anything else as I’m asking for a refund from Zebralight. Let’s see if they will honor my request.

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I still think you need to try making sure the cap is on tight.

My hands tell me it is tight and the fact that the light is bright when it is on means there is enough current to power the light which means there is good contact.