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John another thng that could be affecting yoru laser output is the batteries you are using. rechargables - be they NiCad or NiMH - only put out around 1.2v each whereas any non-rechargable (any that are not flat anyway) put out 1.5v each. So if your laser is like most and uses 2 batteries, you've already robbed it of 0.6v of the 3v supply it's designed to run on - you're trying to run it at 80% power by using rechargables.
Also batteries are affected by the cold too - some batteries will provide way below their "normal" output power when cold. Dewstrap heater for the laser maybe? ;-)
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