Gee golly... I snap a shot of my emitter without even really paying any attention to the minor gap on one side, and now people all over the world are discussing my horrifying misalignment!
😱 Anyway, plenty have stepped in for explanations of what's being seen here, but I figured I'd better offer up my own responses for you wonderful nutters, since I'm the only one actually able to look at it in real life.
I admit that I'm totally OCD about off center emitters - it bugs me, BIG time. Hopefully mine will be better in this regard...
It kind of amuses me that it would be such a big deal, considering that it has no effect on how it performs and isn't even a very obvious cosmetic defect. But then some would say that my tint demands are ridiculous, even though to me it's obvious and a top priority issue. Just goes to show how different we all are in our perceptions, tastes, priorities, and focuses. Since it matters to you, I do hope you strike it lucky and get one that is absolutely perfect, even if it is just an ocd cosmetic issue. However, I hope you'll still enjoy it even if it's not perfect in this regard. Even if it's like mine, I think you'd find it less offensive in person.
I hate to say it, but for some reason I've only seen this problem on more expensive non-china lights. Go figure...
When I see an expensive light with a perfect beam and an led that doesn't appear to sit perfectly center, I interpret it as the manufacturer taking the time to do it right and make sure the actual die is centered despite the large tolerances they're forced to work with; just as seems to be the case here. Getting the entire assembly centered and pretty, as on the cheaper lights, is quicker but incorrect.
I think the golden dragon LED will be more forgiving in this regard.
I took a photo of my Twisty Tr in the same way, hoping to support your idea. Don't think I really did, but you can at least see that there's no offensive gap with this style of led. And, of course, the beam is perfect on this one too... Looking at this shot for the first time, it gives me the impression of being taken at a bit of an angle again, but I'm pretty sure that's a trick of the light. The lighting is all coming from one side, with the other side darker and shadowed, creating a depth illusion. I think this one is at least very nearly perfectly perpendicular, I took a little more time to get the emitter right in the center. Oh and I tried to get this shot extra pink, just for Jeff.
As before, click for larger.
And a note to make it obvious for anyone skimming through here in the future:
This is Not a Clicky photo.
Erm... You guys DID notice the shot is at an angle, not perpendicular to the surface of the emitter, right? You're just pulling SN's leg?
But there really isn't any misalignment in that photo!
Come on, people, am i the only one who can see it's not a straight-on shot?
Edit: I'd swear the reflector opening looks elliptical. But maybe it's an optical illusion...
Honestly, I don't even know. The shot was not taken at any significant angle (the lighting had to be shot in through the crenellations), but I can't guarantee that it was absolutely perfectly perpendicular either, I just quickly snapped the shot before going back to studying. At the photographic propinquity of these kinds of shots, a slight skew of the angle would likely make a significant difference. Looking at the light normally, there is no huge and offensive gap, but that small gap definitely is there on one side. I think a combination of maybe a tiny angle and just seeing it magnified so tremendously does overemphasize the issue. I have a feeling that if those who are very bothered by it were to look at the light in person, they would still notice it and be bothered by it just because that's their perception, but they'd see it as a much smaller issue than a photo 100 times larger makes it out to be. As for the reflector opening being elliptical, I think it could be too, but it is *ever so very very slight* if so; I can't even really say for certain when examining it because there's nothing to accurately compare it to, just a lot of angles that make it difficult to judge. So again, that might be a part of it, but we're talking degrees so small that they're of no practical concern.
. . . the extremely minor misalignment shown in the photo - which is as bad as it gets and is measured in single digit mils - has no visible affect on the beam.
Ha, good to know mine's an extreme example of alignment imperfection.
🙂 But as said, it has no visible effect at all, so it doesn't bother me in the slightest. Purely a matter of (very minor) cosmetic preference. Its function is absolutely perfect, so a little character in the way it comes together is a non-issue to me.
When using super macro, the slightest camera angle will manipulate aspects of perception. SaturnNyne just needs to be a little more
exacting.

:tinfoil:
I'll just say that I'm not worried about an emitter being misaligned in the Clicky. There were no distinct reports of that type of problem with the Twisty, and so I'd say the process for building these lights is well refined.
Hey now! If you'd seen how that shot was taken, I think you'd understand that I had priorities higher than getting the alignment dead on...
😉 You're absolutely right though, only takes a slight angle. And I can't recall ever hearing a complaint about an HDS light not having a perfect beam. Every Henry light I've seen has been beautifully focused, so no one needs to worry if their concern is only from a practical/performance standpoint. For those looking for cosmetic perfection... you'll get it if it happens to work out that way, but it will never be a priority over getting the beam right.