err...please edit posts and add to them, rather than making 4 short posts...
1) diode LED'ing means its dead.
2) i got 700ma drivers (2 chips) because thats all that was in stock, i just desolder one of them
3) it is definitely the diode that is dead. I would need an oscilloscope to see if the driver is producing any diode-killing current spikes upon startup
Sorry for the extra posts,
DTR sent me this link, I've got the diodes soldered together and trying to scavenge a 1 ohm resistor from some old electronics but can't quite identify.
Isn't the whole point of finned heat sinks which are made that way for the transfer of heat to air is for them to be exposed to the air so that can happen? Just my two point one cents.