on further reflection, and thinking maybe the rear brake was a little spongey (I use it 20-30% against the front) I put my best Ninja brake bleeding skills to work and rebled the rear brake. That seems to have helped it move from working one in ten times to nine out of ten, but it would take locking up the rear wheel to get it to activate the brake light. Oh, well.
to hijack my own thread....
I filled in the gas cap lettering. What do you think?
before:

after: