Since I just bought the light and can get a replacement, I think i'm going to wait on the build for now (i need to do some more learning also). Also, I just heard back from GeoMan and looks like the new batteries should be out soon. Here's what they wrote:

"We are now in the testing phase of the new battery manufacturing. If all goes well and the U.S. Consumer Product Safety Commission approves the replacement battery, we will be able to start production before the end of the year. It's going to be a really nice battery and a dramatic improvement over the current battery pack in terms of quality and performance.

Please check our Recall webpage regularily for updates:

http://www.geomangear.com/index.php?main_page=recall "