Hi Everett,
Acutally, I've found that the LED quality isn't the main issue with the Dorcy beam color. The issue there is that it is being overdriven by a large margin and thus exhibits the "overdrive blue" that is standard on 5mm whites with too much current.
I'm sure a nichia would put out more light, but you're almost better off drilling the reflector on it a bit and retrofitting with an underdriven Lux-1. Then you get a significantly brighter light and a much better beam color.
I probably spent ~6-8 hours making my first solitaire pill from the dorcy circuit which, if it were billable time at work, would have paid for my lathe. After the initial learning curve, though, I could get the time down to ~2 hours.
If the dorcy circuit is properly shrunk it can easily fit in the existing, unmodded solitaire. You do need do drill out the reflector though, or use a 3mm LED or grind down and polish a 5mm. It will then easily fit the standard AAA battery.
The problem with just adding more Vin to this circuit is that since it's voltage regulated (not CC) the current to the LED will be far too high unless you're driving a Lux or other high current LED.
I've been considering taking a look at the new Luxeon based "flash" LED's since they are a lot smaller than a standard Lux and have a slightly lower continuous current rating.
A standard Lux is just too large to fit in a solitaire without significant modifications to both the lux and/or the solitaire. The little smt flash lux, however, would fit with room to spare.
It's designed for use as a camera-phone flash at high pulse currents, but is also rated for continuous "flashlight" use at lower currents. The beam pattern would likely need some help, but the size makes it a great candidate for 1xAAA lights.
pb