Aight,
I discovered something very important last night that I should have noticed weeks ago: there are indeed "guardless" bodies that are machined differently than the "guarded" lights. For some reason I had it in my head that Bill had told me that there was some error and they had all gotten machined the same--or else that he didn't have any guardless bodies left--or SOMETHING. So, I didn't even think to look for differences.
But, indeed, there are light bodies that have very slight machining at the rectangular switch hole, with lots and lots of good solid metal all around, where the switch snaps in nice and tight and clean. Beautiful.
J_Oei, your yellow mag body is guardless! So, that's cool! Do I have a current address for you? If not, be sure to PM it to me.
There are 11 guardless bodies, including J_Oei's: 3 silver, 1 yellow, 2 pewter, 4 black, 1 red.
Now, the guarded bodies situation is much less pleasant. The amount of metal left in at the top front and top rear of the hole is absolutely minimumal. Like paper thin--no exaggeration. So, guards that attach firmly and securely to the entire top machined surface of the body are a must. No getting around it. No using an o-ring to take up the thickness. Ixnay on that idea.
We have 13 guards right now, plus 3 empty bodies (silver) with the guards already epoxied in place.
So, that means I can make 27 more USL's with the parts I currently have (not counting battery packs, which I can make more of myself without trouble). This is more than enough to fulfill all the outstanding orders listed in the first post of this thread.
So that's good. However, it means I need to come up with my own attachment scheme for the guards to the guard-machined bodies. I don't like the epoxy route, but it's a viable, tested route and I may just use it.
The consumer grade 3M double sided tape I tried last night would work in a pinch--sort of--but is less than great, to say the least. I'm going to look into using the 3M VHB tape (VHB = very high bond). Chris Reeve Knives uses it to attach the nice wood inlays to the sides of their knives, and it's fantastically strong, and while it is expensive, I won't need much of it. So, I'll look into that, and find out from Bill which epoxy he used.
This won't delay me any longer, as I have three guarded bodies all set to accept internals, and 11 guardless ones, but in the long run, I will need to securely attach guards to some of the guard-machined bodies I have.
So, that's the report. J_Oei, your light isn't ready to go out yet, but it will be soon.