OK, so a quick update, due to manufacturing issues with my CNC guy, cost and just overall hassles driving parts around and such. I have decided to move towards the off-the-shelf parts type of light. This means using the Maglite heads and OMS canisters. You can see these at tlslights.com. I can make these much cheaper (CNC lights were $600 Mag based $450) and don't have to take a "gamble" with my money since I can order parts as-needed and Mags and OMS cans are relatively easy to find. With CNC I had to make a big investment for many heads and cans.
I have completed a 25W SST-90 LED light and I have to say, the more I dive it the more I like it. It does have a pretty big spot, but is able to signal and light up very well. The thing is rated at about 2000 lumens and with a 10 cell pack can run for about 4 hours. I dove mine in about 10-15' vis at the local quarry and it was great.
If anyone is interested in DIY parts, I have a few CNC heads left and a few canisters left for you to build. I will let these go relatively cheap so PM for details.
BTW, don't let the mag heads fool you, these are custom machined heads. Not JB Welded/Epoxy glued together lights. I have placed these in my pressure pot to 265 feet and no problems.
Thanks
Hector
tlslights.com