So I have some crummy news. Due to stupidity on my part, I rushed the process of building this. As this host does not have a set screw, I had to use arctic alumina thermal adhesive to hold the module in place. However, by the time I had epoxied the module in place, I realized I had not yet secured the positive battery contact in place - it was hanging, attached to a wire inside the host. In my frustration (the epoxy was getting harder and I didn't want to have to scrape the epoxy and such out of the inside barrel, etc.), I just dropped a few drops of super-glue down the barrel to hold the battery contact in place.
Over time, it seems that the connection between the battery contact and the positive input lead has broken down (I soldered it, but I think the metal on the battery contact was very thin so it just physically broke), leading to very intermittent effectiveness. Last night, after about an hour of non-working laser usage, I decided to try to open it up. However, the fit was very tight - the module was wrapped in copper wick for a tighter fit for the aixiz hole, but it seems that, due to the greater surface area (the copper wick), the arctic alumina adhesive made a VERY strong bond, much stronger than usual. I had to completely obliterate the diode and driver in order to remove the module from the silver host (includes heating up to 800 degrees, then cooling it very rapidly, hitting it on things, etc.) because I did not want to dent the host.
Anyway, I ordered another diode and have the driver set up. This time, I am going to use a weaker version of the adhesive (mixing 1 part hardener 1 part epoxy 2 parts arctic silver compound) to hold the module in place (doesn't need 2000+ lbs. strength) and I will get a better battery contact.
Anyway, I figured I would shoot that out. I hope the new 9mm diode I ordered does >2.5W too. =o
My 9mm came in today, I'm worried I might rush the build too.