Thanks for the replies and info.
Sure no prob
Sorry for the typo I meant to say that the batteries where 4.16 and 4.17v off my charger.
Oh OK that explains it.
I will discountinue use of my light as soon as the over-discharging protection kicks in (light shuts off the first time). I was at work and wanted to squezze out a little more light to check something.
Still... even with the protection circuit, its generally not the greatest idea to deplete the cells severely enough to "hit" the protection cutoff point. Protection circuits can & do fail, so relying on them solely to prevent over-discharge unfolds a layer of risk. The best approach is a 2-tier. Carry backup cells, and mentally monitor time length of use. Set a fixed time for yourself and after (say) 45 minutes, pull the cells and reload.
I just got a bored 6P from Oveready and will start using 18650s and just use my RCR123s on my single cell lights.
Thats a good idea. Less voltage does not necessarily mean less lumens. But its still not a good idea to regularly deplete single 18650 cells and bump them into their protection cutoff point. You should be aware that protection circuit cutoff points vary greatly from cell to cell. Many are WAY too low... in the vicinity of ~2.5V in some worst cases. So don't think for a second that a protection circuit alone is going to protect the cell.
I would still want to know the safe voltage difference I can use two batteries with different voltage. I used the two RCRs with the .17v difference and it worked fine but discountined use and just put the batteries in my single cell lights.
I can not answer this... as I only use equally charged cells in pairs.
I have noticed the two batteries also dont drain/discharge the same I have taken the batteries out and have seen a gap in voltage difference, so voltages are going to differ as one uses the flashlight at some point regardless if both batteries had the same voltage when off they came off the charger and put in flashlight.
That may be a correct observation, HOWEVER it still is NOT justification for using semi-depleted cells together with fully charged ones. Inter-mixing cells of varying depletion is a proven failure mode... not just on CPF mind you, other industries have also come to this conclusion. No amount of circular logic and reasoning can justify the use of Lithium Ion cells in a proven unsafe manner.
Just remember that there are no "absolutes" when dealing with Lithium cell safety. There is no direct 1-1 (100%) correlation between flame/venting and poor safety procedures. Its more like stacking the odds in your favor. With every miss-followed safety precaution, you are exposing yourself to another layer of risk. You are not going to completely eliminate that risk, but there are definitely things you can do to lessen it. If you choose not to follow proven safe practices... you may get away with it 1,2,3...100 times... but all it takes is once.