Here is a shot of the headlamp with the lens and reflector removed. A.J. reports that some work has do be done to the inside of the headlamp for the components to fit.

Here is the light broken down into its individual components. A.J. carved out the reflector, giving the light a more "finished" look when assembled.

An O-ring was placed between the Luxeon Star and the LM2621, presumably for electrical insulation. This will also add a little impact protection to the assembly.

Here we see a close-up of the LM2621. A.J. reports:

"Running full blast, the Luxeon draws about 430mA (checked with a Fluke meter which adds .2 ohm to the circuit, so the actual draw is a probably a bit higher) ... enough to burn it out. Just wanted to see how bright things could get ... and it didn't destruct! I use it intermittently.

LM2621 Starts winking out after about 1 min. "on" time."

The "winking" is the LM2621 thermal protection circuit kicking in. to prevent this, it would be necessary to modify R2 on the board to drop the voltage output to the Luxeon Star.