"Another mod that works well is to take a small nylon washer and place it around the bulb on top of the switch. Play with the washer thickness to shim out the reflector the correct amount so that the beam is at tight focus as soon as the light turns on. This is much more convenient than turning on the light, then having to search for the focus you want everytime, which for me is always full tightness."
<font size="2" face="Verdana, Arial">Good idea. I tried it on my Mag 2AA NexStar mod running lithium batteries, and it works. But the washer will rattle unless the reflector is pressing it against the bulb platform. If you unscrew the head a little too far--you get a rattle. No big deal unless, like me, you use the flashlight on your bicycle.
So I cooked up another way to do this. I found a rubber plumbing washer in a "Home Washer Assortment" made by Danco and sold at Lowes Hardware (UPC#0 3715580817 5). The washer is 11/16" dia. and 5/32" thick, as measured, and has no hole. I drilled a hole in the center of the washer big enough (and then some) to let the NexStar bulb poke through. Then I installed the washer behind the reflector, jamming it down so that the edge of the washer presses against the threads inside the head of the flashlight. I re-assembled the flashlight to find out what focus/beam I would get. It was too wide, so I took the washer out, sanded the thickness down some, tried it in the flashlight, and did this again and again until the focus was just right--ie, super tight as soon as you turn it on. The washer thickness I ended up with was about 7/64".
Result: perfect spotlight, and no rattle, because the washer is lodged against the inside the walls of the head.
It sounds like work, but actually it was real easy. Rubber is easy to drill and sand, way easier than nylon, and you can get the thickness just where you want it. Maybe you can even find a rubber washer that specs out right to begin with, at a specialty fastener store or plumbers.
The only concern I have is that the rubber may slow down heat dissipation, leading to burnout. I'll post again if this happens.