I think it's just the nature of the creature. Mine used to do that with the original bulb pack.
What I did was replace the bulb with an LED.
Extremely bright, it doesn't just crap out at the drop of a hat like the old one did when the bats went low, and the batteries last for freaking ever now.
Mtnbkr was the one who actually ordered the bulbs; query him for more information.
The LED conversions are great, if you can find one that fits in your flashlight. Last I checked, they don't make aftermarket LEDs for Surefire Executive series lights like mine or Nick's.
You can get rechargeable cr123s and a compatible incandescent bulb for the Executives. They don't solve the sudden-death battery problem, but they do make it economical to always keep the light stoked with fully charged batteries.
As Mike said, I believe it's just inherent in that type of battery. All my devices that use CR123s go out the same way.
Same for me....My camera just stops working....
OK,jfruser...
Cough up where you got that LED for $10!
I'm assuming Ebay...
Thanks!!
Hokay, here's the skinny:
I was considering these two:
http://www.dealextreme.com/details.dx/sku.6090
http://www.dealextreme.com/details.dx/sku.6076
I went with 6076
This guy went with the 6090:
http://www.candlepowerforums.com/vb/showthread.php?t=193639&highlight=surefire+6p+led+replacement+modification+reflector
And one of the posters put a video of how he modded his 6P (with the 6090) on youtube:
http://www.youtube.com/watch?v=uY3bfuxayVw
As a drop-in replacement, neither one allows the bezel to completely screw back on. Some folks just slip on an O-ring to fill the gap, but hte guy with the video did further mods.
And here is the Mother Of All LED Drop-In Mods for the 6P Thread:
http://candlepowerforums.com/vb/showthread.php?t=193992
Good luck. I am happy with my Redneck Engineered 6P.