Thanks for all the info from everyone!
I've started putting together a light out of a Ferei B-12. The one things I'm concerned about is the comment about the safety factor. How was the calculated and what would the results be for the B-12 which tops out at 53mm?
A couple of notes on what I've found so far:
1) The stock driver runs just fine with a piezo switch. This simplifies construction is some ways and not others. My thought is to put an extender on the end with square 1" aluminum. It looks like the existing barrel can be threaded with a 20mm thread. So one end of the extension will be 20mm, the other end threaded for 16mm for the cable gland. The top of extension will get a 5/8 hole for threading in the piezo switch (slightly recessed to keep from inadventent turn ons). The bottom (and the other reason for going square) will get a paddle handle for mounting on a neoprene semi glove.
2) The lens will get replaced with a borosilicate lens that is 5mm thick and probably coated to spread out the light a little more. Looks like there's room for replacing the stock seal in the front, one behind the lens, one on the barrel and one where the front section mates to the barrel. Overkill, maybe - but this is the weakest point.
3) One reason for the threaded-on extension is that there could be a lot of stress here. Over time, any glued connection could fail. Also, there will be o-rings where the two butt together, one internal, the other external. I'm looking at 6061 aluminum, with painting to match the Ferei head. While it start out square it will end up with the end fully rounded and all edges relieved.
4) There will be no power switch on the can, but I think I will put a sealed power connector for charging. This will be covered by a screw on top with a o-ring. Will also likely put a power gauge to monitor charging and dive time. May also put in a water detector with a painted on sensor. Can will be made out of 1/4 acrylic with machined ends out of 3/4 acrylic.
Any thoughts? I certainly would like feedback on the safety calculation done so far.