Hi Sniper -
To answer part of your Q...
10 WATT LIMIT.
The plastic reflector will handle up to almost 10 watts before starting to bubble/star/melt from the bulb hole outwards. The greater the wattage, the sooner that this meltdown will occur. Continuous use of the 30 watt WA1185 will severely melt the reflector in 3 minutes or less, my wife melted the reflector in 7-8 minutes with a 20 watt bulb during a power outage, and the 12 watt CL1057 will eventually melt it as well, though it will take much longer for it to occur.
RE: Carley vs. stock Maglight bulbs...
Carley makes the Maglight bulbs...it's listed in their catalog as Krypton Star and Xenon Star Lamps. Their pricing is much higher than picking up the bulbs at your local Meijer/Walmart/etc.
Some excellent bulbs to run on 3 123 batteries is...
Radio Shack KPR112 - I find this too "fragile" (ie. close to the insta-flash edge) and have settled for the
Maglight Krypton 5-cell bulb. Another good choice is the
Carley 1057 at 6.0v 2.00a you can expect runtime of around 20 - 25 minutes. Another one that NT is refering to is the
Carley 1499 at 7.2v 1.84a which has a runtime of 25 - 30 minutes.
Both of these Carley bulbs run great on 6 rechargable AA nimh in a 2D light. Sooner or later, you'll probably want to replace the lens and reflector, but one can run them for a while before you will start to see signs of melting.
I hope that info helps. PM me if you need some direction on where to obtain the parts.