Well, here's the 473 update.
When I got the laser, immediately, without fail, power the thing on would result in a bright flash of 473, and a quick - within 5 seconds - fade down to maybe 5mW. A trickle. tem01 or more the whole way.
The immediate response was, "This can't be right - Something must have gone wrong in shipping." Glenn talked to CNI, we got set up for an RMA.
I remembered ElectroFreak's writeup on mode hopping - and how it was usually related to power. And it made me think; so I began trying different batteries, different types of 18650s, from 1800mAh to 3200mAh, protected and unprotected. Freshly charged every time, of course. No change. The laser would just spurt and die out.
(Little did I know I was making the problem worse.)
Well, here's where the key change happened. I ordered some 18650's from MrDusanMandic. They arrived overnight as he had promised and, well, really out of nowhere, I decided to pop one into the PGL-III-C-473 50mW without charging it. I turned it on and noticed, "Huh. that looks like more than 50mW". (I had also read Rob's report of good performance in his 473 by then, and duty cycle, and had it kinda floating in my head. )
So, what's up with these batteries? The laser's... bright. Real bright. What's going on here? I run it for 30 seconds, on a white target, looking for dimming and mode hopping. A little mode instability --- no dimming, doesn't really hop to TEM01. Huh?
I grab some of the batteries I had been using the night it had arrived (We've had about 48 hours elapsed now. Some use, and passive drain on those batteries) - when it was having problems - and put them in. Hmm. Another 30 second run, bright as really can be. Almost have to squint. Funny business... Well, don't want to call it good yet. What, did things get knocked back into alignment? Can't be.
I end up down in Boulder with a friend with a Coherent meter and bearing Rob's test in mind, I try it. With the same battery. 90 seconds of 55-75mW. A one minute pause. I fire it up again and watch my watch, and the meter. 60mW.. 77mW ... watching it count past 30... 75mW ... past 90... 70mW ... Wait a minute. This laser really is starting to behave?
I was able to repeat Rob's tests, almost exactly. 90 second runs of 50-75mW. No problem. Repeated them 3 times.
Tonight? Two 2:00 runs without dimming.
So what on earth is going on? Some of those 18650 cells I got from MrDusanMandic I had on the charger overnight to get charged up. Here's where my hunch comes in. I pull one off and stick it on my multimeter. 4.3v??? .. Oh damn.
Pull the other one off... 4.4v ... Check the battery in the 473. 3.8v. Sure enough, I throw some completely different cells on that charger and a few hours later they emerge at 4.5v.
So, what's the big idea? -- I think that this whole time, it's been the charger pushing my 18650's too far. Maybe other lasers weren't sensitive to it but I have a feeling that the pump diode was just overheating so quickly that power would drop out.
I'm not willing to close the case QUITE yet, but it looks good - I want to keep testing; these two 2:00 runs are a really good sign though. This was not possible with the freshly charged cells. And I'm not really willing to feed it a 4.5v cell again. But, I am willing to try new batteries on another 18650 charger (I do have several, this was a DealExtreme TrustFire...)
But right now my PGL-III-473-50 is putting out some serious photons for at least 2 minutes at a time, and, that ain't half bad.
Just wondering what anyone else thinks of the situation and my logic here? Could it be possible, that that's all it was, and that I'm good, going forward? I'd love to NOT have to RMA the thing.