Paul,
I finally got around to doing that E1e mod. I used a drill (I have a Dewalt too) with a 13/32 drill bit. I just put the head in a vice and went SLOW.
I then threw the head together. I used a Q3J and a BadBoy500 with an Ecan and Esink. Pics down below...
On the second pic, it's obvious that the reflector is a little screwed up. This did not happen when drilling out the head. This is the head from my very first Surefire and I tried to clean it.
These are the beam shots and I tried to get a couple that might actually convey a real idea of the beam. I don't think I succeded. The first is about 5 feet from a white wall.
If you will notice, there is a pretty nice hotspot. What may not be clear is that the rest of the frame should be filled with sidespill. To be honest, it doesn't have nearly throw of an NX05 or a modded KL4, but it does have throw and more sidespill than either the NX05 or modded KL4.
The next pic was taken from my kitchen into the utility room. The distance is about 15 feet from the light to the back wall of the utility room.
As you can see, the little BB500 with the Q3J puts out a good amount of light. If you want maximum throw, this isn't gonna get you as much as a modded KL1 or KL4, but if you want some throw combined with a very nice flood, this may be your ticket.
This is a nice alternative to a McFlood. It doesn't get too hot either. It does warm up, but nothing unmanageable.