Thanks, Dave - plenty of pics will be put posted once I'm closer. Found some left over carbon fibre and stainless steel to use for a build once the prototyping is done. In the meantime I've put an old 5mw red into the Art Asylum Phaser case just to have something to play with for the time being. I haven't even got a DMM onto it - just set it up with guesswork and the odd resistor I had running around. The red used to run off 4.5v, so, using its original driver I'm pumping 12v through a 330 ohm (could be 330k - I forget now - will test) resistor. Seems to work fine - very bright (low divergent beam) - I can easily eyeball (at night) the spot on the wall of a house over 1/4 mile away, but can't see the beam at all and it certainly doesn't burn (or even warm) my hand.
Sorry for the thread hijack, HumanSymphony!