I can tell a 40 lumen difference...
So you're saying that you can see the difference between 3000 lumens and 3040 lumens???
Or maybe you mean see the difference between 1 lumen and 41 lumens... I can see that, and so can anyone else....
Most people mistake beam shape and CCT differences for total lumens when making visual comparisons. Side by side, with enough time to experiment (I'm talking about having several minutes and a white wall), I'm sure some people could probably distinguish the difference between 240 and 280 lumen (within the range I suspect you are claiming to be able to see the difference). However, both flashlights would need to have an LED with the exact same CCT and exact same beam shape coming out the front. In actual use, nobody would be able to distinguish the difference. Even a slight difference in beam shape or CCT can make it impossible to distinguish such a difference.
If Malkoff M60 is rated at 235 factual, not paper lumens does that mean that this Wolf-Eyes module is less than 235 lumens?
The MalkOff is pushing a high bin cree to ~1.1-1.2A, any other module that pushes a similar bin cree to a similar drive level is going to have similar emitter lumens, the difference between driving a Q5 or R2 at 1.0A, and 1.2A, is very little in actual performance, it's around 10%. Most of the modules available out there these days are pushing a decent emitter to around an amp.
The MalkOff combines about a 10% gain in efficiency from the TIR optic, and about 10% output from the higher drive level than most competing buck regulated modules. Those factors, combined with the fact that a TIR optic puts more light into the center and immediate spill beam, and less in the "wide" spill beam (where a ton of light goes on reflectored LEDs), can make the MalkOff stand out as a much better performer than many reflector based alternatives, but it depends on your preference. I happen to like the strong spill-beams inherent to reflector LED setups, but appreciate what TIR optics can do when properly selected for an application. So again, I go back to the fact that you really cannot compare the 235 lumens of a MalkOff with a TIR optic to "290" or "280" or "250" or "310" or whatever the latest greatest number that is being plastered on the side of the latest LED drop-in with a reflector. The comparison doesn't matter because the beam shapes are going to be different. In any case, we're talking about a *similar* amount of emitter lumens, and a similar amount of total power consumption. Generally speaking, the MalkOff is going to be brighter in total output than most of the reflector based cree drop-ins by 10-20% depending on what module it is stacked up against.
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Having said all that you do have a number of options that will run on the 4xCR123 as backup.
Wolf-Eyes modules rated up to 13V
Popular R2 dropin from DX (SKU: 11836)
LumensFactory D26 LED 3.6-13V models (available with selected warmer color temps)
DereeLight 1SM-2 or 3SM. (Available in R2 or Q5 or 5A Q2 warm white).
There are probably others, but these are the ones that come to my mind right now... The 3SM with it's 1.2A drive level is probably going to be the most impressive of the bunch, but not by enough difference to really matter IMO, but I have no idea what the actual drive level of the WE module is, the LF and 11836 modules run about 1 amp at the LED.
I'm not sure if it's worth $64 for the Wolf-Eyes module, considering that the MalkOffs are only $50 and are hand made.
Eric