I've been running NIMH's in my Tec40 with overdriven 3.6V .75 Amp Kryptons as suggested elsewhere in this string. They are available at Radio Shack and as the standard Ray-O-Vac 4 cell bulb at WalMart.
I've also been concerned about the long tips on many of the Halogen bulbs. (Read Alan's earlier comments.)
I've ordered some 1.7 Amp 4 rechargeable cell Krypton Carley bulbs. I'll probably use just in Mags if (a) they don't fit, (b)if the AA NIMH's can't handle the draw, or (c) I see reflector deformation.
Curiously Carley doesn't seem to go above .87 amps on Xenon bulbs with PR bases.)
More interestingly, for the Tec40, I've found and ordered the following bulbs at
www.topbulb.com.
HPR44 Halogen 1.0 amp 4.0 volts for 4 rechargeables $2.57 @. Maybe it'll fit and maybe it won't
KPR139 Krypton 1.2 amp 3.85 volts for 4 rechargeables $1.41 @
Shipping on any order is a flat $5.95.
Unlike the Carley's, both of these unusual but standard bulbs probably are designed for prefocused reflectors.
The 1.2 amp Krypton bulb shouldn't present a lens interference problem.
The voltage drop on the NIMH's at a 1.2 AMP draw should mean the 3.85V bulb is much less overdriven than with the 3.6V .75 Amp bulb.
A 1.2 Amp Krypton bulb probably runs cooler than a comparable Halogen bulb. (Maybe that's why I haven't found a PR base halogen pumping out more than 1.0 Amps.)
Assuming that the 4AA NIMH's voltage reduce down to 4.0V with the 1.2 Kryptons. These lamps should run at roughly 4.8 Watts.
If I don't melt anything after these bulbs arrive, perhaps Brock would want to test this configuration.
In any event, have fun browsing the topbulb site.