Swap your latching switch for a momentary switch. The 16mms fit in the boxes. I don't think Tim has added any 12mm boxes yet. The Nano Biscotte doesn't work with latching switches. Don't worry, you won't have to hold the button down to keep the saber on.
BuckPucks need over 5v to run properly, while the NB runs on a single 3.7v battery. If you're giving your BuckPuck enough voltage to run, then you've likely cooked the NB. Use a resistor for your main LED instead.
I'd grab one of the thermal tape pads as well, to help keep your LED mounted to the heatsink.
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