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Aside from the LED position/lint thing, it sounds like a battery issue to me. Check the voltage with a multimeter. If the light stops working, check the voltage immediately, it might have dropped too low. It's also normal for the voltage to recover slightly after being driven hard, which might explain the coming back from the dead, especially if the light itself has low-voltage protection and it hasn't tripped the protection on the battery (although for all I know you might have an unprotected cell).