My H4 CREE 550 Lumen LED Invention (and Smoke)

I received my "tactical" mounting rails for my monster LED flashlight today. RATHER than sticking with the plan of mounting the rail and sharing the light between motorcycle and bicycle, the temptation to put the 3 LED element into the DOT housing was too much. A proper H4 "LED" upgrade MUST be in the works somewhere in China, so I went for it to make my own.

1. I removed the bulb element from the existing H4 to expose the base and 3 wires. I isolated the case using electrical tape, cut the "low beam" wire to get it out of the way and had 1 wire to the center and 1 to the lamps aluminum case.
   
2. I then "welded" the lamp and H4 base using many wraps of the electrical tape, put the H4 LED into the housing, put the housing into the fairing (removing the mount points for the silly rails) and put the fairing on the bike.
3. I traced the headlight power wire and jumped it from the extra "RUN" position wire I have providing 11 volts. BRIGHT light, BUT then it started to flash like a bicycle blinker.
4. I fiddled around a bit to see if I built an RC circuit or something, but always flashing. I then wired directly to the first series battery, more flashing and faster.
5. I then jumped to the flashlight batteries and housing to see what maybe happened. No more flashing, but the brightness was way down. Was I overvolting or ??
6. Back to configuration of step 1, no flashing but dim. Every on-off of the lights now had one flash, then dim and dimming light.
7. Rather than the RUN switch tap, I tried directly off the DC-DC. More behavior as in step 6, one bright flash during "On" at the switch.
8. Back to the flashlight batteries. Flash on on, then nothing. At this point I assumed I broke something.
9. Confirmed something indeed was fried, original flashing of bright light just was not going to happen.
10. Took the fairing off, and the H4 LED invention out. I spelled burned PCB board.
11. Took the H4 LED apart and documented each step with the camera. More stinky.
12. Put the flashlight together again. I get a single bright flash from the LEDs, so I assume its circuitry vs LEDs.

The big mistake? FUSES, hello, and too much voltage.

Original Flashlight: 3.7 volts, 2400 MAH each LI-ION battery * 2 = 17.76 Watts-Hr Capacity. To fuse, I need to know peak amps. Assuming the light would go for 1 hour, thats 2.4 Amps at 7.4 volts - a 2 amp fuse inline with my futzing around would have been a good idea.

Anyway, lets see if the vendor has any lamps/spare parts available. I will try to insert pictures to explain th e construction above. For a brief moment, it was looking like the right solution, so I am saving my H4 base.