I know this is an old thread, but I thought I'd interject since I just discovered it. I got brave and tried to RCRs in my TLR-1 after reading this thread. It worked. No poof. No white smoke. However, it didn't seem much brighter, and the potential of your cells giving out or the protection circuit kicking in during a life or death situation far outweighs saving a few dollars. Maybe for practice drills, using RCRs wouldn't be too bad, but if you use your gun for defense, whether in the home or on the streets, I would never trust rechargeable batteries. Oh yeah - and the switch is solid. My TLR-1 is an original and I've used and abused it on my 870 pistol grip, firing hundreds of rounds of 12 pellet 1280fps police buckshot, dropping the gun on the hard floor and having it land RIGHT on the light (this is steel framed 870 with a fully loaded Mesa Tactical 8 round side saddle - 14 rounds out the door). I have activated that switch thousands of times at least and it still looks and functions as new. It's the absolute best deal in firearms lights out there... period... and trust me, I own and have tried out MANY dedicated weapons systems. The Blackhawk Serpa thing is junk. I resold it on Ebay after about 2 days of owning it - purple beam, flimy design, offset light... Don't even bother with anything cheaper than a TLR-3, which is excellent (and much easier to change the batteries on). I had a Surefire X200 that I was extremely disappointed in. It seemed poorly finished and flimsy compared to the TLR-1. Holes were drilled slightly off center, screw threads still had burrs. The Anodize wasn't even, and I couldn't even tell any real difference in output for a light that cost twice as much. Streamlight's dedicated weapon lights are the only ones in their lineup that I can recommend over Surefire. OK.. enough....
Shao