Billson, I don't think you're right that a $140 flashlight can't have problems. If you buy a $100,000 Jaguar, I guarantee you it will spend more time in the shop than a $12,000 Toyota. The same goes if you buy a $5000 Minerva wristwatch instead of a $50 Casio. The FF is a wonderful design but it's made in runs of a few hundred pieces, not 1000's of pieces like the Arcs. Also, lots of them are sold semi-complete, which means the fit between the light and the sandwich is left somewhat up to chance. Making a light reliable mostly means very consistent manufacturing processes, which means large production runs; or else, lots of hand assembly and adjustment, which would make it a $500 light (the auctioned LL123's sold for about that much) instead of a $140 light.
In my semi-complete FF1, there's a tight fit between the sandwich and bezel, and the optic isn't seated properly in the bezel so it's a little loose. Also, the light doesn't work with Energizer brand CR123's because they're a slightly different length than the Yuntongs I'm using now. (The Arc LS 1x123 twisty tailcap may have been discontinued over similar issues). Finally even with the two-level switch removed, the on-off action is a little bit twitchy. Maybe I didn't do such a good assembly job and I need to figure out how to tweak some things, that Doug would tweaked if I'd bought a turnkey FF, but that leaves me tweaking again if I ever swap modules or optics.
Even with these issues, though, it's still a nice, useful light, that I like to carry and to show to people. Maybe I can get Doug or Wayne to take a look at it sometime and see if its minor issues can be dealt with.