The last time I dealt with this stupid headlight, I made things work with some ridiculous construction techniques. Well, those construction techniques finally made something die. I still had a full set of parts, and the schematics in an EDA tool, so I laid out a PCB to try again with more reasonable construction techniques. The schematics and layout are in their own git repo. The tools were gschem and pcb from the gEDA project. Somebody told me to look at oshpark for the fabrication, and 3 copies of my board cost me $4. Deal. The fabbed boards look nice:


And assembly wasn't a giant pain:


If this breaks for some reason, I really should just buy another light.