Re: KL4 vs KL1 Physical Size (Dept. of Trivial Questions)
Note that there is no "-" between 'KL' and '4' etc. It's KL1 not KL-1 for example.
Also (i don't know if this is right, just a guess) that the KL1s electronics are actually a vertical board instead of a circular board that is horizontally oriented within the light.
It seems you are confusing the LED bezels with the L2 (and old L1) bodies.
The PCB's used by the KL bezels is all orientated the same way.
The difference between the KL1 and KL4 is the LED size - the KL4's large LuxeonV LED compared to the KL1's smaller LuxeonIII LED.
The diameter of the KL1 is essentially the same as the KL4 - It's the length of the bezels that is different.
The beams produced by the KL1 and KL4 are so different that its not really possible to compare them - that is to say it is not really practicable to use the other LED/beam generation type in order to generate the beam of the first.
If you wanted to create the beam of the KL4 using a LuxeonIII & TIR - the bezel would likely have to be wider diameter.
If you wanted to create the beam of the KL1 using a LuxeonV & reflector - the bezel would likely have to be both wider diameter and longer.
Al