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Lodberg said:
I've checked the bulb - it's a 6407370-OSRAM which is 6.5V, 0.849A which gives 5.53W.
With my 5 rechargeable cells I get 6V and NOT 7.5V as I get with alkalines. So do I have to few volts and will that effect the torch's performance?
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Lodberg, probably a noticeable difference in output. Incandescent bulbs are influenced heavily by voltage. The chart below shows a rule-of-thumb relationship between voltage, output and bulb-life.
The difference you'd notice will depend on just how much voltage the bulb is actually getting from the alkalines. At nearly 1 amp, probably less than 7.5 volts but I don't know how much of a drop. I suspect the design somewhat overvolts the bulb. At 6 volts, you'd be significantly under-volting. As a hypothetical example compare the "luminous flux" line at 90% vs. 110% of nominal voltage. That represents 70% vs 140% of the "normal" output of the bulb. So, if the alkalines supplied, say 7.2 volts to the bulb they would put out twice the light of the 5 x NiMH pack at 6 volts. And the light would be significantly whiter.
If this doesn't work for you, you might find success by using 6 of the rechargeables. That might present a space problem and then you'd need to think about maybe using smaller cells or modifying to gain space for an additional D cell.
On the other hand the 20W bulb seems to be designed for 5-cell NiCad pack (probably a 5 or 5.5V bulb) so if you were to use that bulb, 5 NiMH cells would provide the intended voltage. The only question then is if the non-rechargeable version can handle the heat/amperage of the 20W bulb. They both have metal reflectors so probably ok as far as the reflector goes.