Sorry to hear about the problems people! Let me see if I can respond to each:
1. Packaging. Yes, the packaging is simple. We would like to provide fancy retail-ready blister packs in a month or two. Cost and time is the determining factor. The LS birth is taking a lot of our resources. For now, we shoot for packing that protects the light during shipment. We haven't heard of any being damaged by shipping yet- and would be surprised in that event. Frilly packing is very important for retail impulse sales, and it is coming (our resellers have been asking for it for some time).
2. Gap between head and body, length of threads. This is something we have been tweaking since day one. We have changed those dimensions 4 times. The goals are:
<UL TYPE=SQUARE><LI>Cover the O-ring in the off position
<LI>Limit accidental head separation
<LI>Support wide variety of battery brands
<LI>Keep the light working as the battery compresses over it's lifetime
<LI>Keep the switch and interface reliable, compact and cost effective
[/list]
The latest version should meet all those goals quite well. We reached the gap distance by taking the shortest AAA brand we could find and just barely having it make contact. That said, you still might find a battery that is too short to reach. It's a trade-off. Otherwise, the gap would be huge.
We have had a problem with some of the battery compartments being shorter than specified from the machine shop. This affects about 2 in 100 units. We spot most of them before they get out the door. The machine shop is correcting the defect (they say it is caused by out of spec bar stock). If your o-ring is not completely covered when you twist the light off 1/4 turn, send the unit back for replacement please.
As far as changing the switch design to work in reverse, that would require an additional switch assembly. Would be very nice to have.
Very important note: There is a reason this is the shortest AAA light in the world. We had to make some compromises to get that point. Even so, we have lengthened the light slightly with each revision (for a total of about a tenth of an inch) to make room for certain improvements. Adding a switch or reverse-on mechanism will add to the length. Then we would be back to the length of the Mag Solitaire...
I designed this light for my uses. My goals where to make it small and bright while using the smallest *cost effective* battery available. I have been repeatadly called obessive about not wanting to make any changes that would increase the size and length of the light.
Even so, I have agreed to some minor size increases to make room for some other improvements.
If enough people ask, we could release a longer, "bells and whistles" version. I however, will continue to use the robust and compact version.
3. Strange corrosion in battery compartment. Unless your unit is an older one, this shouldn't happen, these leave here shiny clean. Now, we did have a bad batch a couple of weeks ago (some of the 2.0's) that required us to sand out the compartments to clean them up. Even so, there may have been residual white/green gunk. Send for replacement please.
This happened because the gasket failed during anodizing. That was the nail in the coffin so we nixed the gasket and switched to the o-ring (good riddance).
Other than that, the only other explanation is a bad battery. Judging on replacements, this seems to be pretty rare though.
4. MIA battery retainer ("foam thingy"). Yes, these will come off. That is why we offer lifetime free replacements of o-rings and battery retainers. Before we switched from light oil to silicon grease, we did have a higher number of these falling off. We switched to the grease right after we switched from gaskets to o-rings (v2.1).
What about making them stick better or using another solution? Sure. We are always improving the product. We are seeing an improvement now that we have switched to silicon grease. We are also looking at changing the adhesive to something a little more tenacious.
If we had a reverse-on/etc switch mechanism, the battery would be spring loaded and therefore less likely to rattle anyways. But that would have to fit in the longer, "bells and whistles" version.
Of course, we could pull a [competitor's single cell LED flashlight] and nix the battery retainer all together. But we are perpetual perfectionists.
5. O-ring getting loose over time. Yes this happens with all o-rings. We haven't heard of it happening yet with the Arc-AAA, but we expect it. Ditto on the lifetime free o-ring replacements.
6. Anodize/lettering quality. We use industry standard black anodizing with laser inscription. To make the lettering sharper and the finish shinier, "bright dipping" or "electro-polishing" might help.
7. Beefy wall thickness. So, is this a bad thing? We made these tough for a reason. We have rolled over one of these with the front tire of a 18-wheeler tractor. Haven't heard of one yet that got crushed, mutilated, etc. Goodie.
8. Crooked LED. Yes, they are all slightly off center. All mounted LEDs are off center slightly. The question is, how much? The way we have improved trueness is to close up the gap around the LED so it is held more snuggly. We did this starting with verion1.0 and are still making tweaks. There is some deviation among the LEDs (not all 5mm LEDs are actually 5mm, even among the same type, etc).
We do hand test each light. We spotted one today in fact that was off center too much. Please ask for a replacement if you get a bad one.
Keep the input coming! Thanks!
Peter Gransee