Torch useful run-time is about 1 hour which is more than enough for home use (this drops the battery to about 9v), the battery should not be discharged below 7v, apparently it's not good for them. I also modified the charger by removing the LED's from the circuit board placing them in a separate box which indicates power, charging, and complete. These chargers vary greatly and I was lucky enough to find one with LED's.
The whole project was really fun and simple to make (basic understanding of circuits) and now I have something which is powerful and reliable plus the satisfaction of having made it myself.
Some materials used:
Banana clips, 2x male and female. 2 female for base of torch and 2 male for charge cradle. Just line them up properly so they fit nicely.
Rubber stoppers for charge cradle feet.
Aluminium (12mm x 3mm) for handle, Panel sealer strips and heat shrink for grip.
2.5 gauge automotive wiring.
One could substitute the halogen for a cluster LED bulb which would provide possibly 15 hours or more per charge.
With the addition of new photos, I've added a smaller flashlight which I just made. Uses a smaller gelseal battery and LED cluster bulb. The housing is an electronics enclosure which is perfect.