TRC, your followup post above and apparent lack of email from you got me thinking that you might be waiting for me to respond to your original post here on the cpf and in an itemized, issue by issue way. I prefer to dialogue with a person one on one (chat, email, phone, in person). The forum is more of a broadcast medium designed to service large groups of people. Oh well.
I have your post open in a seperate window so I may refer to it as I respond to each item...
Oh, I should preface this by saying, just because a feature is that way doesn't mean you should have to live with it. That is why I say the light isn't for all people in all usage. In that case, please take advantage of our return policy.
1) The LED is off center. Not a lot; about the same as my old style $15 CMG Infinity....which cost about 1/3 the $$$, of course. You can see a space on one side of the LED, and rolling the light causes it to project little circles of light.
Yes, the LED is off center. I can just about guarantee that. This has been discussed here on the CPF for years. You see, the die is not even perfectly centered with the lead frame and epoxy package. This is an LED manufacturer issue. Now if the beam is wide and diffuse, the effect is more hidden. Nichias are better centered than most, but they also use a more optomized phosphor which means you see more of the rings of the blue LED underneath. Have you seen the beam of a narrow beam blue LED? It will seem strangly remeniscient. Some manufacturers glop on a bunch of phosphor. This smoothes the beam but reduces the total output. Phosphor can cut the output of the blue LED by 30% or more. So its a balance like everything else.
Now you said that the off center beam makes a circle when you turn the light. This means you probably are not talking about the rings in the beam but instead the arc that the center hotspot makes as it traces an off center circle on the wall. Every LED we get does that. No surprise there. What we do is pull out the worse offenders. Each and every Arc-AAA is roll tested at 6 inches. If the center spot deviates by more than 1 inch, it is pulled. I bet you dollars to donuts your light passes this test.
With the new Arc-AAA, we are using a new 2-step centering jig designed by Merri's dad. This process involves centering the package of the LED with the housing noticably better than what we used before. I can see this in the roll tests. We are having less variation. Of course, Nichia has probably also improved the centering of their dice with the new CS LED. There is still variation but it is measurably less on average.
The fact that you can find a cheaper light with a similiar beam pattern just tells me they are also using a 5mm LED, probably one of the nichia models in fact. The extra quality of the Arc is apparent in many areas, but it is not a panacea for everything.
2) The head has a gritty feel as I turn it. Not what I expected from a $40 flashlight, especially from Arc.
This is tough one. During assembly and then in inspection, each light is turned on an off repeatidly. I just don't know if what you are feeling is normal or the light was damaged in shipping, or a chunk of dirt got in the threads, etc. It is hard to speculate. You might clean the threads and then relube them. This might noticably improve their feel. Or, we might replace the head/body for you and that does the trick. That is why I prescribe the service process of emailing me, sending the light back, us checking it again, etc.
I kid you not, we test these lights like a paranoid obssesive. In fact, I have been criticised by our accountant, investors, people visting the factory for mercilessly applying those obssesive standards. I have been asked to reduce my standards repeatidly. People will tell you I am quite stubborn. /ubbthreads/images/graemlins/smile.gif It never fails though, we check a light and finally send it out and bam! The customer finds something wrong with it. Our first thought is, what did you do to it!? I only conclude there are a million possible interactions a person can have with a piece of hardware. Sometimes we missed something but the majority of cases (I know everyone thinks their's is different when it happens to them, but the numbers don't lie) are not a failure of our manufacturing or QC process. The number one problem is battery leakage. I see that as a design problem actually. A perfect light would be impervious to any type of thick gunk forming on the contacts. Still work to do in that area. /ubbthreads/images/graemlins/smile.gif
In the mean time, the important thing to me is keeping our promises. Did we say the light will be different to all the other lights on the market and be impervious to the effects of thick acidic gunk? No. But when it happens, we fix the light anyways. Usually the customer is grateful, sometime they think we owe it to them. No worries.
3) With the lithium L-92 from Energizer, it practically takes a pair of vise grips to turn it on. Every other Arc-AAA I've ever owned, or handled, could be relatively easily turned on with one hand. I have small hands, with excellent dexterity in my right hand, and the strength of a considerably larger hand. The is no way I will EVER be able to turn this on with one hand.
Ok, that is just not right. I assume it is much easier to turn with the duracell provided? In that case, it does sound like a screw up on our part. Lithiums are larger in diameter. We found out the other day that some of the battery compartments are out of tolerance (we are talking less than 1 out of a 100) at the base of the tube. I visited our factory in Phoenix yesterday where we machine the parts and I talked to the owner about the problem and instituted more frequent tests (we were testing 1 out of 50) of that dimension. To catch any that get through (check and balances always), Merri also added a test on the final assembly. Any units that did get out, those customers are being sent a new battery pack. However, we don't know if you got one unless you tell us. So far, only one person has emailed me about this and he should have the pack at his doorstep today thanks to fedex.
Please don't shoot the light out of a gun. Let us take care of it. I suggest either a refund or maybe a new battery pack will bring satisfaction.
Peter