I believe the subject of how long a WeaponLight lamp should last, and why we recommend not weapon-mounting handhelds, has been discussed here before, but here goes:
If your lamp failed after one magazine it is defective. Call SureFire customer service at 800-828-8809, they will have some questions to verify the situation, then they will give you a return merchandise number and a ship-to address for the lamp. They need to receive the old lamp first to verify that it is in fact defective, if it is they will send you a replacement.
The tungsten filament on an incandescent lamp is the weakest link in any manufacturer’s light. Tungsten has certain properties that make it difficult to draw into wire consistently. Every so often you will get a lamp that has a weak filament. That is the nature of tungsten and also one of the reasons we recommend using a shock-isolated system for weapon-mounted applications.
Taking your lamp/bezel off during daylight training will of course extend the life of your lamp. You don't have to take it off, but you can.
Can you mount a handheld to a M4? Yes, but you will not get the same lifespan from your lamp as you would with a shock-isolated system.
Two lower priced SureFire WeaponLights (shock-isolated of course) to consider include the 660 Classic Universal system that comes with a barrel mount and a momentary tape switch ($312 MSRP), or the M951C Millennium Universal system that mounts to a Picatinny rail, is waterproof, MilSpec hard anodized, and has a momentary/click-on/click-off pushbutton switch ($286).
As far as SureFire lamps breaking before those of other manufacturer's.... well I'm biased of course (I work for SureFire), but that is contrary to what I have experienced during my extensive use of our products and those from other manufacturers. I am posting below the text of an e-mail from a customer; his experience is typical of most of the feedback we get:
"Howdy,
I’m on a Special Forces team over in Okinawa Japan. A few months ago we received M900A series WeaponLights for our M-4s and have been using them off and on since, but (until two days ago) we have not really had a chance to see how they would hold up to heavy shooting.
Here is where the lights really proved themselves. We had a flat range for two days and had approximately 2,800 rounds of 5.56 per man. We did a lot of team drills, ambushes and the like that involve very fast and full-auto shooting. Many times our guns heated up to the point that even the M900A's handles were very hot to the touch.
I thought for certain that two days of such shock, heavy firing and tremendous heat buildup would have some adverse effect on our lights. I am very happy to say that the lights worked great! They were not loose at all after almost 3000 rounds, much of it on full auto.
The operation was fine and the main and LED bulbs were stable and bright as ever. That light is built like a tank and nuke-proof for sure.
Thanks for building such a great light SureFire! In my line of work – it really brings peace of mind knowing that, no matter what the conditions are; you can depend on your equipment.
-- D.K.
1st Special Forces Group, Okinawa Japan"