Today, I have mailed out O-rings to all those who already have a Killer in their possession, along with a little note.
I've found two things to do that will eliminate the flickering.
First, file/sand down the solder blob so that it is only .5mm tall (yeah, yeah, I know I said to make it thicker before; and, in fact, I did increase the thickness to stop the head of the light from contacting the top of the battery--but that was before the PEEK sleeve installations). Doing that allows the two pieces to move very close together when the light is turned on; and then, when the light is turned off, only the very top of the O-ring should be visible, if not completely hidden by the battery tube. I also found that a flat solder blob seems to twist the battery less, thus giving a more "instant on" experience, rather than any flickering when the battery is first contacting the solder.
Second, install the 1mm x 9mm O-ring in the bottom of the battery tube, then reinstall the battery. The O-ring provides just a little more space to keep the battery from the negative button on the bottom of the battery tube when the light is unscrewed. And, please unscrew the battery tube by three to four ticks of the grooves when shutting your Killer off.