In reply to wercat:
I would like to admit to being your phantom disliker!
You say your improvements have made your petzl zoom better than when it was new - I'm not surprised.
Although revolutionary in 1981, they are in fact crap by modern standards - I bet I could make something better too from off the shelf parts, and I can barely change a lightbulb.
The best response to anyone with a problem with a 7+ year old headtorch is to buy something modern.
Tesco do one for a fiver that is better than the original tikka/tikkina - buy four, and you'll have a lighter, less bulky and more redundant system than a zoom.
If you want a good light, buy a modern petzl - bomproof, compact and bright.
Anyway, that's why I disliked your post (now removed). Because it was poor advice for 95% of people.
I do actually admire your skill and tenacity in keeping it going. And I hate letting fixable stuff die, but beyond a certain level it's a hobby, and not practical or economical in terms of time.