Yes, very good work there, Probedude! I just have a simple multimeter so all I can do is swap batteries (for a different voltage level) and do a tailcap test. That info is eye opening!
I took my Rebel MagLED completely apart yesterday and compared it to my previous generation MagLite with MagLED drop-in module. It's interesting to note that the head is the same on this new one as it is on my old one but the main tube is different. The threads don't go down as far and the O-ring sits closer to the end of the tube. When you screw the head down all the way the top of the tube is not flush with the collar inside of the head like on the older one. It sits about a quarter inch lower, presumably for more clearance for the deeper reflector. Yes, the entire light is about a quarter inch longer than the incan one. The tailcap and head are identical and I can swap between them if I want to. The switches are, obviously, not the same but the switch assembly is almost identical, the difference being a small projection on one side of the button side of the switch so that the switch itself cannot be mounted upside-down. Also, the switch assembly isn't as long meaning that the batteries sit about an eighth of an inch closer to the bezel on Rebel MagLEDs compared to the older Mags. I plan on taking comparison pictures of these as well as my '80s MagLite but I left my camera at my brother's house over Thanksgiving so it will have to wait.