db,
I'm thinking that starting off with a smaller host is the way to go. Cramming D cell NiCD's in there will reduce the weight a bit, bit it will still remain a huge clumsy light. If you extrapolate this to the X990 which uses NiMH (with a 70 minute runtime), it's still a pretty heavy light (about 7 lbs) and also a bit clumsy (without as nice of a spot as the Thor). Eh, I think the 2 hour runtime of the Thor is pretty useful, trying to reduce the weight a bit will likely be very hard. Starting with a smaller host may be easier.