Can this be done with a G2 Nitrolon out of the box or does it need to be modified i.e. different bulb?

It works (I've done it) but you have a reduced bulb life.  Adding the Z32 Shock Isolate Bezel helps alot.

But even then you won't be protecting the bulb from the batteries slamming into it.

If your a civie just protecting your home - then its probably worth the risk.  But for an LEO or prof Warrior I'd buy the weapon light as it has the features needed to prevent the batteries from hitting the bulb.

I've had a G2 in a Fobus mount on an AR for around 4000 rounds. I would not want a flashlight for any purpose that couldn't stand the negligible recoil of an AR.

I use a G2 in a heavy duty scope ring on my shorty 16" AR fore end rail.
I've only put about 500 rds thru it, but I've had no problems.

Has anyone used the TDI mount for the G2?  It's a mount that can use the rail mounting system.  It's made of plastic and looks pretty tough but I've never used it.

Also, who here has actually first hand experience with failure of the G2 light when mounted to an AR/M16?

G2Z with a 1 inch ring atached to sure-fire m16 mount on service entry gun.
500+ SS109 no problems yet.
Battery runs out in one hour.
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my anwser:

It Works GREAT!!!   i love mine, ive had one mounted on my m16 for about 2 years now.  i use the rail adapter mount, (retail for about 25$)    never ever had a problem with it.  it withstands everything from shooting to being dropped out of the back of a truck (idiot squadmates not me)    if you are planning on getting one i would also suggest getting the spare carrier that surefire makes for it.  holds 6 batteries and an extra bulb.  can be a real lifesaver.  as to the life of the bulb i havent noticed any big difference between the one on my weapon and the on i carry on my webgear.   hope this helps.

I've had mine on for awhile now. I have not put any serious rd count's threw it thought. I plan on Leaving it on for all my shooting this year to include a Carbine class in July 04. After that I will post results of my test to see how it holds up. it's hard to beat for $30 bucks. But I do agree with the poster who said it's OK for Civies but for Hardcore users get a weapon light designed specific for that purpose. I think that's awesome advice.