Ok, here goes...
I have built custom battery packs for my SF 9N and new UltraStinger and have been using them for over 1.5+ yrs (9N) with no issues. However, they take some work to assemble and a special charger to charge. Some details:
- Sanyo RC2400 NiCd Cells $8 each (US=5 cells, 9N=3 cells)
- Approx 80-90 min constant runtime from both 9N and US
- Ability to fast charge with no issues
- No Bulb Issues
- Slightly Higher Perceived Brightness than regular pack
- Super tough, Super proven
- 9N pack was easy to build
- US Pack took a lot of work...
Charging:
Unfortunately, the US Charger puts out only 0.18mA, which will charge an empty 1800mAh battery in 15-16 hours. However, 1/10 rate charge is recommended for NiCd trickle charging so I don't know how this would work for the Sanyo 2400mAh batteries. At the very least it would take a lot longer to charge, as in a day or so. I don't know about cell damage by charging at such a low rate, but you never know. If you are going to invest in a super-battery, you might as well buy a correct charger for it. These can be had starting from $25 or so.
If you already have a RC car charger, then this will probably work for a US battery pack, just make sure it can handle the 2400 battery and 4 cell packs.
3000mAh NiMh batteries: I am not sure about how their discharge curves will work with a flashlight bulb. I would assume longer life with probably a less bright beam. Bad for the bulb? I don't know, maybe. However these batteries are getting better and also gaining more acceptance in RC circles so I may try a new super long life pack for my US sometime...
If anybody wants me to expound on the details of building a US pack, let me know and I'll see if I can remember.