I've been wondering about overdriving a AAA as well and I have some comments and questions.
I've noticed that the explosive force venting or explosions that are fairly rare but serious are usually preceded by an error by the user or a defect of a light component and that this predominantly occurs with multiple cell Li ions.
The reverse charging under high load of one cell to another is a main cause of explosive venting. This can be caused by mismatched batteries or charge levels.
For purposes of this thread we are assuming a single cell, overdriven a bit perhaps but it can't get to a reverse polarity forced charge and vent situation.
I assume a single cell Li Ion is much more safe even when being used against recommendations, and although they too can vent if for instance you get them shorted out somehow, overcharge them (this isn't in the light so leave it out as a problem), or run them with too much current load.
Yes, it can get hot and vent if you are using your AAA light for long periods, but if you just want to dazzle yourself intermittantly and with the knowledge that this is an overdrive (and use lower levels on your light) then I think the worst that could happen is that it gets very hot, starts to vent, and maybe vents in a way that damages your light.
I haven't heard of a single cell explosion like you would get with a multiple cell reverse polarity type rapid explosive venting where the body of the light itself is subjected to so much force you have shrapnel detonation.
I'm guessing the worst that would happen with a single cell is the head popping off or a broken lens/reflector damage.
Am I wrong?
I'm considering getting a Illuminati TI which I probably would not overdrive because of the heat dissapation with titanium, although I might use lower levels and high for a few seconds I suppose. But the one I was thinking of buying to overdrive was the LD01, It should dissipate the heat well, and if used for less than a minute at a time (actually it's rare for me to use any light for longer than 30 seconds), which is my habit, I think it's fairly safe, although of course, you can't say it is proper use or completely safe.
Am I right that single cell Li Ions are much safer? and that lower time usage should be fine?
Of course I know the side issue is that the LED life will be shorter (but still relatively long)