Gentlemen,
I truely hope that this is not a pandora's box I am opening here. None the less I hope that the "truth shall set you free" holds here. Suspecting that there is nothing wrong with the lights mentioned above I offer the following possible explaination. Nichia currently makes the NSPW500BS and sorts these LED's into three brigtness ranks; Q,R & S. Their current policy is to provide their customers these LED's with no provision for requesting specific ranks. It is my understanding that there are few if any Q LED's in the pipeline now.
According to Nichia Specs, the min luminous intensity on the R rank can range from 4800 mcd to 6800 mcd whereas the S rank can range from 6800 to 9500 mcd. Typical values are 5600 and 8000 respectively.
I venture to say that the above quoted ranges may explain the variations you have noted above, ceterus paribus.
I hope this information will be accepted by members of the CPF for what it is. For what ever reason, Nichia has chosen not to post this information on their web site and the lack of this information has caused errant speculation. I am not a flashlight manufacturer but I can't sit idly by and read about concerns of the quality of a great flashlight when the likely fault lies elsewhere. As I understand Nichia's current position, a flashlight manufacturer could place an order for 20,000 LED's and find that the shipment consists of equal parts of Q,R & S intensity ranks. Would you have the flashlight manufacturer absorb 50% of the shipment as a loss? Until Nichia has real competition in the white LED arena, they have the luxury of conducting business as they see fit. Nichia could destroy many of the LED's that fall below what we would like to see but that would probably mean that every LED would just cost that much more. I'm frankly grateful that the white LED's are even available and as technology improves and prices go down more and more LED's will be efficiently lighting our world.
Since Nichia does test and rank their their LED's it would be nice if they offered them for sale by rank.In the case where a single LED is used in a high quality flashlight a premium could be paid by the manufacturer and then the consumer.
I think it is important to understand that Peter Gransee and others are pushing the technology the best they can with the materials available to them.
Most important:
"I have been a proud owner of an Arc LE for the last 8 months."
Has anything changed with this light? Life is relative.
Should I have kept my keyboard still and not written this?