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@Ludd
Have you tried wrapping some card round the battery holder? Or putting a section of inner tube round the battery holder? the spring connectors in these lights are a bit weedy and if the battery holder is allowed to rattle about, the connectors seem to disconenct, if you see what I mean. A bit of a bodge, but it might help.
Edit: oops, I've now read above and see that this has already been covered. Ignore me!