Hey.. i have a much cleaner solution to this problem (or at least often a solution).
I had a problem with my current project.. the 10430 batteries are like 1.5mm shorter than a 'true' AAA.. and the head doesn't turn on enough to make contact with the battery normally.
I started with some pretty crude solutions, but with enough trial and error came up with a fantastic solution, and it's related to my 'rubber band powered arc aaa' concept (wrapping a rubber band in aluminum foil and dropping it in the bottom.. it makes the engagement so much more clean and reliable and the 'feel' is so much nicer.
In any event, i didn't want to send out final work with as 'crude' of a solution and came up with something muuuch cleaner.
1) the batteries i have for the project come with tabs.. don't want tabs so i have a bunch of these battery tabs...
2)... I take a little rubber self-stick dot.. like you put under something you don't want to scratch your furniture.
3).. I wrap this strip around the dot.. .. which is 'dome' shaped.. so the ends wrap around to the sticky bottom.
4) this leaves enough 'sticky' to stick to the bottom of the flashlight body, and also holds the strip in place.
It works amazingly well. The lights have such an awesome 'touch and feel' now, and i got the extra height i need and don't have to mod the battery.
-awr