For that setup with 6 aa's your basically looking at 7.2 V nominal after rest or under load, but up to 9V after a full charge. (This assuming 1.2 V per cell nominal, and up to 1.5 hot off the charger).
For a 6 Volt bulb that is best over-driven at about 7.2 V (1400 lumens vs. about 750 for the stock 6V manufacturer recommended Voltage) you only have about a half of a volt before it gets to a probable insta-flash. I like to think of flashing a bulb as just a really high performance incident with a remarkably short run time. I think most are not interested in this particular bulb putting out about 4000 lumens for 300 milliseconds.
Chart pic. Compliments of Lux Luthor's Destructive Bulb Testing here
http://www.candlepowerforums.com/vb/showthread.php?t=179748
You really have to be careful which means, ideally a soft start switch which defaults to low when un-powered (like AW's does I believe). Then you can use it fresh off the charger at a lower setting, and then crank it up under load after a while as needed. Alternatly you will have to do what MrArtillary says for direct drive and rest and test your pack, or use 5 cells instead of 6. I would think that lithium cells would only make your voltage situation even more volitale and less flexible for this voltage sensitive application. It's a nice bulb, but it is very voltage sensitive for over driving.
If you look at some of the other bulb charts in Lux Luthors Destructive Bulb Testing thread you will see some other 6V based bulbs that can be overdriven a bit more before flashing which might help a bit, Notably the ROP 6V and the Osram 64430, there is another bulb that looks good too but I think it's kind of hard to get, and probably more expensive when you find a supplier (the GE bulb). Also some of the bulbs won't fit in the bi pin adapter, some will.
SIDE NOTE: I just got one of these AW switches, and although I'm still training my fingers to do the right things ( I unconsciously try to turn it off with a single click and it just changes levels) I LOVE it for my M*g85. I usually use the 60% level and sometimes the 30% for moderate needs but it's nice to have the full throw/brightness capability. It about triples the amount of time before I need to charge it.
I just bought another one for a M*G 623 build I am doing. I don't want to start fires, I want a light that I can use on lower levels that has a shock and awe capability built in. I am going to do alot of reflector experimentation to see if I can overcome the ugly artifacts that this bulb has.
P.S. Lux if your seeing this, I am not rushing you but I just feel bad for your poor neglected Capacitive discharge spot welder, they require alot of love and attention.
