Thanks for taking the time to go into such details with the photos included, greatly appreciated. After seeing your photo, I realized how to take out the switch casing, simply by removing the rubber button and pushing it out (I was worried about tearing the button but obviously it isn't an issue). Anyway, back to the mod - there are some design differences in these lights, for one my LED heatsink assembly is actually threaded into the battery case instead of the head, so the only form of adjusting its depth would be by not threading it in fully. Also, the tailcap appears quite a bit different on mine, for one thing it looks like your tailcap is more deeply threaded into the battery tube vs. mine, and also my switch holder is designed differently than yours. Mine has a conventional spring attached to the switch's clip, though the rest of the switch holder is designed differently as well.
It's confusing to explain the apparent differences and my camera isn't very good with closeups, but it's near to physically impossible after the measurements I just took on mine. With just the switch set into the tailcap with no holder and no tab/battery contact, the measurement to the LED's heatsink from the back of the switch is about 67-68mm. Zero margin to work with even not including the tab on the switch or any holder for the switch. I do think it can (and will
) be done but it will be a very tight fit. If any holder for the switch is used, it will have no more depth than the switch itself so it would just serve to keep it centered basically, and the tab on the switch will be folded flush with the back of the switch. So to summarize, basically just the back of the switch w/no holder or contact/spring puts you at approximately 67mm on my Ristoft. Using my LYCKEBY tailcap with just the switch gave me maybe 1 extra MM.
Talk about cutting it close. Where did you buy your Ristoft? Mine is silver, I'm pretty sure I bought it from Fifthunit and it was at least a year ago I'd say. Maybe the current Ristoft from DE is designed more like yours and would be easier to mod. If anyone can confirm if their recent Ristoft sounds/looks more like mine or Nitroz design, I'd be interested in hearing what you think.
Thanks again Nitroz, hopefully this at least proves helpful for others doing this mod.
A couple other quick questions from my first post - should I be concerned about putting anything on the back of the Cree star to keep it cool, or do I just swap them out and be done with it? And is there anything simple that I could add to the circuit in the positive or negative leads that will improve the performance, or should I simply swap the stars, resolder the leads, and nothing more? I guess if there was anything I'd be concerned about it would be overdriving the Cree, or if something added to the circuit would improve battery life without costing anything in output/brightness. I'm clueless when it comes to these circuits and what would be beneficial though, which is why I ask. Or would a straight swap be a good enough mod right off the bat?
Sorry for the ridiculously long post.....