Skids, if you haven't talked to shiningbeam about your difficulty, I would do that. I'm sure he will have some ideas.
I am enjoying my PLI. Had a bit of trouble with the cheapo 18650, but after wiping the battery ends thoroughly it started making contact.
Right now I'm wearing my PLI on my head. Yup, turned it into a 700 lumen headlamp! :party: I sell stuff in schools and we had some cheap plastic no-name-brand 12-LED headlamps we sold. I was cleaning off the damaged item shelf and there were 8 bad ones, so I took 'em inside and tried 'em all with fresh AAAs... found 1 that worked! But I got looking at the other 7, wondering what I could do with them. They have an elastic strap around the head and another over the head that ends in a sewn loop around the other strap... it just slips thru the loop. I've been looking at the Jakstrap and the Nite Ize headbands, almost ready to buy one. And the idea came to me!
I slipped the PLI through the stretchy elastic loop in back, and put the thing on my head sideways. BINGO! The brightest headlamp I've ever seen. It holds the PLI securely enough, although it wiggles up and down a bit when I walk. Angle is easy to adjust by moving the light forward or back in the loop, or side to side by moving the elastic harness a bit on my head. The PLI is long enough that the bezel is about even with my face so I don't get any spill glare. Works with my 2AA Romisen RC-P3 and even the tiny RC-C3 (although the latter must be worn higher up on my head at a rakish... stylish?... angle to avoid the glare).
If any of you have a cheap little headlamp, especially one that quit working, maybe you can put it to better use also!