I got a couple of these flashlights last week. The 18650 is very long.
In your original design ...
How are you making the positive connection? Are you going directly from the center post of the atty through the spring to the top of the battery?
How are you making the negative side connection? Scrape the paint off and pass the connection from press fitting the atty to the push nut then passing it to the aluminum housing?
Positive connection is basically straight to the center post of the connector... It's been different every time; sometimes, I replace the center post with a screw or nail that's been cut down to size or I make the post longer with some wire or a nail... It's mostly trial and error on the original ones. The ones with the side mounted atty connection are wired though.
Negative connection is carried through the body of the flash light like it was originally. I've only run into an issue with the paint/finish once on this weird three-piece flashlight...
These 18
500 batteries are often overlooked. They will fit in most of these flashlights with very little trouble and for the average vaper 1600mAh should last a day.
I'd thought about building some for 18500s since they would basically drop right in and the amount of work would be cut down substantially. If more people at work keep bugging me to make these for them, I may go that route... Personally, I'm all about overkill though, and if I was content with 1600mah, I would have just gotten some 17670s for my XHaler and called it a day...
Additionally, I've attached a photo of the latest one that I've built... Three-piece flashlights make the construction really easy and make for the cleanest builds.