Hi Chop,
Thanks for chiming in. For true throw of course your KL-L3 is still further out there, I'm just demonstrating the wider beam of the SBP that still throws quite well, casting a clear pattern on a tree out behind my backyard that's a measured 47 yards away. Actually I would say the beam of the KL-L3 is quite evenly in between the PM6 McModule's Q2H with its pencil-narrow beam, and the wider yet slim-conical beam of the SBP.
The body is 3-1/2" long, and the edge of the switch cap is pre-drilled for a small split ring or similar.
Current should be around an amp just like yours except via boost rather than buck, and yet with the Fraen it does make a very different beam (and I am wondering if there is room enough to drop a Fraen over the Luxeon in your mod). In fact is the KL4 reflector easily removable the way it is set up now? If so I may try it to see what happens with the TWAK/Fraen combo.
In the SBP the optics are all interchangeable (NX-05, Fraen 6 & 30, McFlood), just gotta watch for overtightening the head when playing musical optics. Heat is approximately the same as for all overdriven little lights, it matches the stock L4's thermal characteristics (up to 160F if left by itself on a table!) except it reaches this in a slightly shorter time. I'll do some published results once the production converters get here, these hand-soldered proto boards may not be as precisely built...