I am afraid I should have logged in and read about your little voice before I continued my testing ... it appears that I may have shorted out my Catapult's circuit by over-tightening the reflector housing.
I was setting up to do the 1x18650 runtimes, when I noticed the beam pattern seemed a little unfocussed. Thinking the head was unscrewed, I started tightening it and the light suddenly cut-off. The light now runs in direct-drive only, with no regulation or control circuit.
My best guess is that the aluminum reflector was able to short the contacts around the emitter, despite the plastic insulating disc. ThruNite was quick to respond, and a replacement is being sent out to me by courier.

So I should be able to get those 1x18650 runs done for everyone in a couple of days. And bonus - I will be able to compare to see if there's any sign of inductor whine on the replacement (ThruNite thinks the first one may have been faulty, as they are not generally experiencing any whine issues).
For now, I suggest that everyone be careful not to over-tighten the head!
I'll keep you posted - thanks for the quick replacement ThruNite!
An interesting point - I noticed when I opened the head of my light that the o-ring here was broken (despite a lot grease being present). Of course, my over-tightening could have contributed. Thrunite also suggests that the o-rings may also be weakened by excessive heat, so it's probably a good idea to keep an eye on the one in the head.
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